T-SB-0075-13 Service Bulletin/Repair Instructions

•\
@TOYOTA

T-SB-0075-13
Technical Service Bulletin
May 30, 2013
MIL "ON" OTC P0401

Service

Category
Engine/Hybrid System
Section
Emission Control
Market
Toyota Supports ~

ASE Certification ~
USA
Applicability

YEAR(S)
MODEL(S)
2010,
Prius PHV
ADDITIONAL INFORMATION
2012

2012
Prius V
2010-2012
Prius
Introduction

Some 2010 - 2012 model year Prius vehicles equipped with a 2ZR-FXE engine may exhibit a

MIL "ON" condition with Diagnostic Trouble Coae (OTC) P0401 (Exhaust Gas Recirculation Flow

Insufficient Detected) present. The Exhaust Gas Recirculation (EGR) Valve has been improved to

address this condition.

Production Change Information

This bulletin applies to vehicles produced BEFORE the Production Change Effective VINs shown

below.

MODEL
ENGINE
Prius
PLANT
PRODUCTION CHANGE EFFECTIVE VIN
Tsutsumi
JTDKN3DU#C0335785
Toyota Auto Body
JTDKN3DU#C5474775
2ZR-FXE
Prius V
JTDZN3EU#C3149807
Tsutsumi
Prius PHV
JTDKN3DP#C3019094
Parts Information

PART NUMBER

PART NAME
QTY
Valve Assy, EGR
1
25627-37010
Gasket, EGR Valve
1
25634-37010
Gasket, EGR Pipe
1
PREVIOUS
NEW
25620-37110
25620-37120
© 2013 Toyota Motor Sales, USA
Page 1 of 4
®TOYOTA
T-SB-0075-13
May 30, 2013
Page 2 of 4
MIL "ON" OTC P0401
Warranty Information

OP CODE
DESCRIPTION
TIME
OFP
T1
T2
EG1307
R & R Exhaust Recirculation Valve
1.9
25620-37110
BA
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 Recirulation 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

Pennsylvania and Washington, the Exhaust Recirulation 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 Recirulation 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.
Required Tools & Equipment

REQUIRED EQUIPMENT
SUPPLIER
Techstream 2.0*
PART NUMBER
QTY
TS2UNIT

ADE
TIS Techstream

Techstream Lite
TSPKG1
1
TSLITEDLR01
* Essential SST.

.
NOTE

• Only ONE of the Techstream units listed above is required.

• Software version 8.10.021 or later is required.

I
• Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE) at

1-800-368-6787.
© 2013 Toyota Motor Sales, USA
@TOYOTA
May 30, 2013
T-SB-0075-13
Page 3 of 4
MIL "ON" OTC P0401
Required Tools & Equipment (Continued)

REQUIRED MATERIAL
QUANTITY
Heat-resistant Vinyl Tape
As Needed
Repair Procedure
1. Use Techstream to check for DTCs and confirm the condition is present as described in the

Introduction.
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 I 2011 I 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 I 2012 Prius PHV:

Engine/Hybrid System - Emission Control - "2ZR-FXE Emission Control:

EGR Valve: Removal"
• 2010 I 2011 I 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 I 2012 Prius PHV:

Engine/Hybrid System - Emission Control - "2ZR-FXE Emission Control:

EGR Valve: Installation"
© 2013 Toyota Motor
Sales, USA
' .. ~.

@TOYOTA
T-SB-0075-13
May 30, 2013
Page 4 of 4
MIL "ON" OTC P0401
Repair Procedure (Continued)
3. Modify the wire harness using the following procedure.

A. Remove the vinyl tape wrapped around the

main harness and the EGR harness.
Figure 1.
B. Wrap the exposed zip tie 7 - 8 times with the heat-resistant vinyl tape.

Figure 2.
Figure 3.
C. Connect the EGR harness to the new EGR Valve.

4. Clear all DTCs using Techstream, test drive vehicle, and confirm that no pending codes are

present.
© 2013 Toyota Motor Sales, USA

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