T-SB-0027-16

T-SB-0027-16
March 31, 2016
MIL "ON" DTC P0401 and/or Rattle After Cold Soak
Service
Category
Engine/Hybrid System
Section
Emission Control
Market USA
Applicability
YEAR(S)
MODEL(S)
2010, 2012
Prius PHV
2012
Prius V
2010 - 2012
Prius
ADDITIONAL INFORMATION
SUPERSESSION NOTICE
The information contained in this bulletin supersedes SB No. T-SB-0075-13.
The entire bulletin has been updated.
Service Bulletin No. T-SB-0075-13 is Obsolete and any printed versions should be discarded.
Be sure to review the entire content of this bulletin before proceeding.
Introduction
Some Prius, Prius V and Prius PHV vehicles may exhibit a vibration due to rough idle and/or
tapping noise from the HV transaxle at cold start. The Check Engine Light may also illuminate
with (DTC) P0401 (Exhaust Gas Recirculation Flow Insufficient Detected). Due to excess carbon
build up at the valve assembly, the valve will stick causing the engine RPM to fluctuate. Follow
the procedures in this bulletin to address this condition.
Production Change Information
This bulletin applies to vehicles produced BEFORE the Production Change Effective VINs
shown below.
MODEL
Engine
PRODUCTION CHANGE EFFECTIVE VIN
Prius
Prius V
JTDKN3DU#C5491168
2ZR-FXE
Prius PHV
JTDZN3EU#C3159675
JTDKN3DP#C3023590
© 2016 Toyota Motor Sales, USA
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MIL "ON" DTC P0401 and/or Rattle After Cold Soak
Warranty Information
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
EG1601
Reprogram Engine ECU
R & R Exhaust Recirculation Valve
Modify Wire Harness
2.4
25620-37120
8A
54
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.

For California specification Prius and Prius PHV vehicles sold, registered, and operated in
Arizona (’12 MY only), California, Connecticut, Maine, Maryland (starting with ’11 MY),
Massachusetts, New Jersey, New Mexico (’10-’11 MY only), New York, Oregon, Rhode Island,
and Vermont, the Exhaust Recirculation Valve is covered under the California Emission
Warranty. This warranty is in effect for 180 months or 150,000 miles, whichever occurs first,
from the vehicle’s in-service date.

For California specification Prius and Prius PHV vehicles sold, registered, and operated in
Delaware, Pennsylvania and Washington, the Exhaust Recirculation Valve is covered under
the California Emission Control Warranty which is in effect for 84 months or 70,000 miles,
whichever occurs first, from the vehicle’s in-service date.

For California specification Prius V vehicles sold, registered, and operated in Arizona (’12
MY only), California, Connecticut, Maine, Maryland, Massachusetts, New Jersey, Oregon,
Pennsylvania, Rhode Island, Vermont, and Washington, the Exhaust Recirculation Valve is
covered under the California Emission Warranty. This warranty is in effect for 84 months or
70,000 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.
Parts Information
PART NUMBER
PART NAME
QTY
04004-58137
Kit, EGR Valve
(Valve Assy, EGR)
(Gasket, EGR Inlet)
(Gasket, EGR Pipe)
(Gasket, EGR Valve)
1
25685-37010
Gasket No. 1, EGR Cooler
1
00451-00001-LBL
Authorized Modifications Label
1
© 2016 Toyota Motor Sales, USA
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MIL "ON" DTC P0401 and/or Rattle After Cold Soak
Parts Information (Continued)
MODEL
MODEL YEAR
ECU PART NUMBER
PREVIOUS
NEW
2010
89660-47300
89660-47301
89660-47302
89660-47303
89660-47304
89660-47305
89660-47306
2011
89660-47430
89660-47431
89660-47432
89660-47433
89660-47434
89660-47435
2012
89660-47510
89660-47511
89660-47512
89660-47513
89660-47514
Prius V
2012
89660-47400
89660-47401
89660-47402
89660-47403
89660-47404
89660-47405
Prius PHV
2012
89660-47590
89660-47591
89660-47592
Prius
PART NAME
QTY
Computer, Engine
Control
–
1
NOTE
The ECM (PCM) should NOT be replaced as part of the repair procedure.
© 2016 Toyota Motor Sales, USA
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MIL "ON" DTC P0401 and/or Rattle After Cold Soak
Required Tools & Equipment
REQUIRED EQUIPMENT
SUPPLIER
PART NUMBER
Techstream 2.0*
Techstream Lite
QTY
TS2UNIT
ADE
Techstream Lite (Green Cable)
TSLITEPDLR01
1
TSLP2DLR01
* Essential SST.
NOTE
 Only ONE of the Techstream units listed above is required.
 Software version 11.00.017 or later is required.
 Additional Techstream units may be ordered by calling Approved Dealer
Equipment (ADE) at 1-800-368-6787.
 The Diagnostic Tester is NOT recommended for flash reprogramming.
Please use Techstream or an approved J2534 interface to perform flash
reprogramming updates. Visit techinfo.toyota.com for more information
regarding J2534 reprogramming.
SPECIAL SERVICE TOOLS (SST)
PART NUMBER
QTY
GR8 Battery Diagnostic Station*
00002-MCGR8
1
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
* Essential SST.
© 2016 Toyota Motor Sales, USA
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March 31, 2016
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MIL "ON" DTC P0401 and/or Rattle After Cold Soak
Calibration Information
ECU CALIBRATION IDs
MODEL
MODEL YEAR
PREVIOUS
NEW
34715000
34715100
34715200
2010
34715300
34715700
34715400
34715500
34715600
34728000
Prius
34728100
2011
34728200
34728500
34728300
37428400
34734000
2012
34734100
34734200
34734400
34734300
34725000
34725100
Prius V
34725200
2012
34725500
34725300
34725400
Prius PHV
34740000
34740100
© 2016 Toyota Motor Sales, USA
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MIL "ON" DTC P0401 and/or Rattle After Cold Soak
Repair Procedure
1. Use Techstream to check for DTCs P0401 and confirm cold start misfire or rattle condition is
present as described in the introduction. If DTC’s or Condition are NOT present, this bulletin
does NOT apply. Continue diagnosis per Repair Manual procedures.
2. Remove and replace the Exhaust Gas Recirculation (EGR) Valve with the updated part.
Refer to the Technical Information System (TIS), applicable model and model year
Repair Manual:

2010 / 2011 / 2012 Prius:
Engine/Hybrid System – Emission Control – “2ZR-FXE Emission Control:
EGR Valve: Removal”

2012 Prius V:
Engine/Hybrid System – Emission Control – “2ZR-FXE Emission Control:
EGR Valve: Removal”

2010 / 2012 Prius PHV:
Engine/Hybrid System – Emission Control – “2ZR-FXE Emission Control:
EGR Valve: Removal”

2010 / 2011 / 2012 Prius:
Engine/Hybrid System – Emission Control – “2ZR-FXE Emission Control:
EGR Valve: Installation”

2012 Prius V:
Engine/Hybrid System – Emission Control – “2ZR-FXE Emission Control:
EGR Valve: Installation”

2010 / 2012 Prius PHV:
Engine/Hybrid System – Emission Control – “2ZR-FXE Emission Control:
EGR Valve: Installation”
3. Modify the wire harness using the following procedure.
A.
Remove the vinyl tape wrapped
around the main harnesses and
EGR harness.
Figure 1.
© 2016 Toyota Motor Sales, USA
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MIL "ON" DTC P0401 and/or Rattle After Cold Soak
Repair Procedure (Continued)
B. Locate exposed zip tie.
C. Wrap the exposed zip tie 7 – 8 times
Figure 2.
Figure 3.
with heat resistant vinyl tape.
D. Connect the EGR harness to the NEW EGR valve.
© 2016 Toyota Motor Sales, USA
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MIL "ON" DTC P0401 and/or Rattle After Cold Soak
Repair Procedure (Continued)
4. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 4 below. Confirm if the ECM (PCM) calibration has been updated. If the calibration
ID listed is NOT the latest ECM (PCM) calibration — go to step 5. If the calibration ID is the
latest, go to step 7.
Figure 4. Location of Authorized Modification label for 2010 - 2012 Prius and 2010, 2012 Prius PHV.
1
Replacement ECM (PCM) Part Number
(i.e., 89681-76011)
4
Date Completed
2
New Calibration ID (i.e., 37601300)
5
This SB Number
3
Dealer Code
© 2016 Toyota Motor Sales, USA
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MIL "ON" DTC P0401 and/or Rattle After Cold Soak
Repair Procedure (Continued)
Figure 5. Location of Authorized Modification label for 2012 Prius V.
1
Replacement ECM (PCM) Part Number
(i.e., 89681-76011)
4
Date Completed
2
New Calibration ID (i.e., 37601300)
5
This SB Number
3
Dealer Code
5. Flash reprogram the ECM (PCM).
NOTE
The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain
battery voltage at 13.5 volts while flash reprogramming the vehicle.
For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8
Instruction Manual located on the Technical Information System (TIS), Diagnostics –
Tools & Equipment – Battery Diagnostics.
Follow the procedures outlined in Service Bulletin No. T-SB-0012-13 ―Techstream ECU
Flash Reprogramming Procedure,‖ and flash the ECM (PCM) with the NEW calibration
file update.
© 2016 Toyota Motor Sales, USA
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MIL "ON" DTC P0401 and/or Rattle After Cold Soak
Repair Procedure (Continued)
6. Install the Authorized Modifications Label.
A. Using a permanent marker, enter the following information on the label:
 ECM part number [Refer to the Parts Information section for
the NEW PART NUMBER]
 Calibration ID(s) [Refer to the Calibration Information section for the NEW
CALIBRATION]
 Dealer Code


Repair Date
Change Authority [This bulletin number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in
Figures 4 and 5. The Authorized Modifications Label is available through the MDC,
P/N 00451-00001-LBL.
7. Confirm the repair.
© 2016 Toyota Motor Sales, USA