T-SB-0036-16

T-SB-0036-16
Rev2
May 12, 2016
MIL ON With DTCs P0A94, P324E, P0A1A, and/or P3004
Service
Category
Engine/Hybrid System
Section
Hybrid/Battery Control System
Market USA
Applicability
YEAR(S)
MODEL(S)
2012 - 2017
Prius V
2010 - 2015
Prius
ADDITIONAL INFORMATION
REVISION NOTICE
July 17, 2020 Rev2:
 Applicability has been updated to include 2015 – 2017 model year Prius V and 2015 model year
Prius vehicles.
January 31, 2019 Rev1:
 The entire bulletin has been updated.
Any previous printed versions of this bulletin should be discarded.
Introduction
Some 2010 – 2015 model year Prius and 2012 – 2017 model year Prius V vehicles may exhibit a
MIL ON condition with Diagnostic Trouble Codes (DTCs) P0A94, P324E, P0A1A, and/or P3004,
indicating a malfunction has occurred in the inverter assembly with converter. Follow the Repair
Procedure in this bulletin to identify the specific components within the inverter assembly with
converter that need to be replaced and address this condition.
© 2020 Toyota Motor Sales, USA
Page 1 of 7
T-SB-0036-16
Rev2
May 12, 2016
Page 2 of 7
MIL ON With DTCs P0A94, P324E, P0A1A, and/or P3004
Warranty Information
OP CODE
DESCRIPTION
TIME
EL1602
R & R Inverter Assembly With Converter
2.0
EL1603
R & R IPM Transistor
2.9
EL1604
R & R IPM Transistor and MG ECU
2.9
OFP
T1
T2
G9200-#####
8A
73
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.
 For California specification Prius vehicles sold, registered, and operated in California,
Arizona (2012 model year only), Connecticut, Maine, Maryland (staring with 2011 model year)
Massachusetts, New Jersey, New York, Oregon, Rhode Island, and Vermont, warranty is
in effect for 180 months or 150,000 miles, whichever occurs first, from the vehicle's
in-service date.
Parts Information
NOTE
 This section is for reference ONLY. The parts listed below are NOT all required for inverter assembly
with converter repairs.
 Order the correct part number by entering the VIN number into the Electronic Parts Catalog (EPC).
PART NUMBER*1
PART NAME
QTY
G9200-##### (Order by VIN)
Inverter Assy, W/Converter
1*2
G920H-##### (Order by VIN)
Computer Sub-assy, MG Control W/Bracket
1*2
G920J-52010
Sensor Sub-assy, Inverter Current
1*2
G9208-47090
Wire Sub-assy, Inverter
1*2
04899-47021
Transistor Kit, Power Module Intelligent (IPM)
1*2
08826-00100
Seal Packing or Equivalent
1*2
00272-SLLC2
Super Long Life Coolant
1*3
04899-47060
Plug Kit, Inverter Drain
1*3
90430-18008
Gasket
1*3
*1 Part numbers are subject to change. Order the correct part number by inputting the VIN in the EPC.
*2 Refer to step 3 in this Service Bulletin to determine if the part is required.
*3 Required for ANY Repair Procedure in this Service Bulletin.
*4 NOT required. Available in case of breakage.
*5 Included in IPM Kit. Available if spare is needed.
*6 Used ONLY for IPM replacement. Part has shelf life of one year. Do NOT use if stored past one year.
© 2020 Toyota Motor Sales, USA
T-SB-0036-16
Rev2
May 12, 2016
Page 3 of 7
MIL ON With DTCs P0A94, P324E, P0A1A, and/or P3004
Parts Information (continued)
PART NUMBER*1
PART NAME
QTY
G922L-47010
Cover, Inverter Signal Connector
1*4
91551-80618
Bolt, Flange
15*4
091X1-47020
Seal, Masking, No. 1
1*5
08887-02809
Toyota Thermal Grease X-23-7884-4
2*6
*1 Part numbers are subject to change. Order the correct part number by inputting the VIN in the EPC.
*2 Refer to step 3 in this Service Bulletin to determine if the part is required.
*3 Required for ANY Repair Procedure in this Service Bulletin.
*4 NOT required. Available in case of breakage.
*5 Included in IPM Kit. Available if spare is needed.
*6 Used ONLY for IPM replacement. Part has shelf life of one year. Do NOT use if stored past one year.
Required Tools & Equipment
REQUIRED EQUIPMENT
SUPPLIER
Techstream ADVi*
Techstream 2.0
Techstream Lite
PART NUMBER
QTY
TSADVUNIT
ADE
Techstream Lite (Green Cable)
TS2UNIT
TSLITEPDLR01
TSLP2DLR01
*Essential SST.
NOTE
 Only ONE of the Techstream units listed above is required.
 Software version 15.00.028 or later is required.
 Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE)
at 1-800-368-6787.
© 2020 Toyota Motor Sales, USA
1
T-SB-0036-16
Rev2
May 12, 2016
Page 4 of 7
MIL ON With DTCs P0A94, P324E, P0A1A, and/or P3004
Required Tools & Equipment (continued)
SPECIAL SERVICE TOOLS (SST)
PART NUMBER
QTY
Oil Seal Puller*
09308-00010
1
Anti-static Mat*
09890-47010-01
1
Squeegee*
09891-47010
1
Torque Wrench Adapter*
09961-00950
1
Inverter Case Separator*
09891-47020-01
1
01413-00072 (Medium)
Electrical Insulating Gloves*
01413-00073 (Large)
1
01413-00074 (Extra Large)
*Essential SST.
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.
Repair Procedure
1. Confirm the condition exists.
A. Are DTCs P0A94, P324E, P0A1A, and/or P3004 stored?

YES — Continue to sub step B.

NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
B. Does the vehicle exhibit physical
damage to the inverter assembly with
converter in the location shown?
 YES — Continue to step 2.
 NO — Go to step 3.
Figure 1.
© 2020 Toyota Motor Sales, USA
T-SB-0036-16
Rev2
May 12, 2016
Page 5 of 7
MIL ON With DTCs P0A94, P324E, P0A1A, and/or P3004
Repair Procedure (continued)
2. Replace the inverter assembly with converter.
Refer to TIS, applicable model and model year Repair Manual:











2010 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Inverter With Converter: Removal / Installation”
2011 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Inverter With Converter: Removal / Installation”
2012 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Inverter With Converter: Removal / Installation”
2013 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Inverter With Converter: Removal / Installation”
2014 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Inverter With Converter: Removal / Installation”
2015 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Inverter With Converter: Removal / Installation”
2012 Prius V:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Inverter With Converter: Removal / Installation”
2013 Prius V:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Inverter With Converter: Removal / Installation”
2014 Prius V:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Inverter With Converter: Removal / Installation”
2015 Prius V:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Inverter With Converter: Removal / Installation”
2016 – 2017 Prius V:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Inverter With Converter: Removal / Installation”
A. The repair is now complete. Clear ANY DTCs and confirm the condition is no
longer present.
© 2020 Toyota Motor Sales, USA
T-SB-0036-16
Rev2
May 12, 2016
Page 6 of 7
MIL ON With DTCs P0A94, P324E, P0A1A, and/or P3004
Repair Procedure (continued)
3. Determine the correct components to replace based on the inverter assembly with converter
type, DTC, and information code.
Refer to TIS, applicable model and model year Repair Manual:

2010 / 2011 / 2012 / 2013 / 2014 / 2015 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Hybrid Control System: DTC Check / Clear”

2012 / 2013 / 2014 / 2015 / 2016 / 2017 Prius V:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Hybrid Control System: DTC Check / Clear”
4. Repair the inverter assembly with converter.
NOTE
 ALL repairs in this Service Bulletin require super long life coolant, an inverter drain plug kit,
and a gasket.
 Toyota thermal grease is ONLY used for IPM replacement. This part has a shelf life of one year.
Do NOT use if stored past one year.
 Reference the Quick Training Guide for best practices for 2010 – 2015 model year Prius and
2012 – 2017 model year Prius V vehicles.
Refer to TIS, applicable model and model year Repair Manual:

2010 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Power Module Intelligent Transistor: Removal / Installation”

2011 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Power Module Intelligent Transistor: Removal / Installation”

2012 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Power Module Intelligent Transistor: Removal / Installation”

2013 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Power Module Intelligent Transistor: Removal / Installation”

2014 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Power Module Intelligent Transistor: Removal / Installation”
© 2020 Toyota Motor Sales, USA
T-SB-0036-16
Rev2
May 12, 2016
Page 7 of 7
MIL ON With DTCs P0A94, P324E, P0A1A, and/or P3004
Repair Procedure (continued)






2015 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Power Module Intelligent Transistor: Removal / Installation”
2012 Prius V:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Power Module Intelligent Transistor: Disassembly / Reassembly”
2013 Prius V:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Power Module Intelligent Transistor: Disassembly / Reassembly”
2014 Prius V:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Power Module Intelligent Transistor: Disassembly / Reassembly”
2015 Prius V:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Power Module Intelligent Transistor: Disassembly / Reassembly”
2016 – 2017 Prius V:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Power Module Intelligent Transistor: Disassembly / Reassembly”
5. Clear ANY DTCs and confirm the condition is no longer present.
© 2020 Toyota Motor Sales, USA