T-SB-0204-12

October 17, 2012

Headlamp Durability Enhancement
Service
Category

Vehicle Exterior

Section

Lighting (ext)

Market

USA

Applicability
YEAR(S)

MODEL(S)

2010 – 2011

Prius

ADDITIONAL INFORMATION

Introduction

Some 2010 – 2011 model year Prius vehicles may exhibit a condition where a halogen low beam
headlamp bulb lifetime is shorter than customer expectation. A modified wiring harness is available
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.

Parts Information
PREVIOUS PART NUMBER

CURRENT PART NUMBER

PART NAME

QTY

N/A

82114-47010

Engine Wire No. 4

1*

82999-52010

Same

Sleeve Tube

1*

82999-30010

Same

Heat Shrink Tube

1

* One per affected side.

© 2013 Toyota Motor Sales, USA

Page 1 of 10

T-SB-0204-12

Page 2 of 10

October 17, 2012

Headlamp Durability Enhancement

Required Tools & Equipment
PART NUMBER

QTY

00002-06000-01

1

Terminal Removing Tool “F”

09991-00510

1

Wire Crimper*

09042-2C100

1

SPECIAL SERVICE TOOLS (SST)

Plastic Pry Tool Set*

* Essential SST.

NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
TOOLS & MATERIAL

QUANTITY

Nylon Ties

13

Measuring Tool (Metric Ruler)

1

Heat Gun

1

Figure 1.

6
1
2

8

5

7
3

4

8

1

Terminal Removing Tool “F”

5

Remove Violet Wire Harness from Connector

2

Headlamp 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

© 2013 Toyota Motor Sales, USA

T-SB-0204-12

October 17, 2012

Page 3 of 10

Headlamp Durability Enhancement

Repair Procedure

1. Replace inoperative headlamp bulbs. After confirming headlamps work, verify headlight aim
seems visually correct, and there is no sign 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.
Please diagnose per the Repair Manual.

2. Remove the front bumper cover assembly.
Refer to the Technical Information System (TIS), applicable model and model year Repair
Manual:
• 2010 / 2011 Prius:
Vehicle Exterior – Exterior Panels/Trim – “Exterior Panels/Trim: Front Bumper: Removal”
NOTE
If the vehicle is equipped with headlight cleaners, be sure to drain the washer fluid system
before bumper cover complete removal.

3. Remove the affected headlamp assembly.
Refer to TIS, applicable model and model year Repair Manual:
• 2010 / 2011 Prius:
Vehicle Exterior – Lighting (Ext) – “Lighting (Ext): Headlight Assembly: Removal”
4. 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. You will be cutting the harness
and using a special crimping tool to make an adequate crimp. It is important to use the
suggested crimp tool and follow the instructions below to assure a proper crimp.

A. Remove the green “cap” from the headlamp
connector.

Figure 2.

This can be accomplished by carefully using
a small screwdriver or pick to detach the cap
as shown in Figure 2.

© 2013 Toyota Motor Sales, USA

T-SB-0204-12

Page 4 of 10

October 17, 2012

Headlamp Durability Enhancement

Repair Procedure (Continued)

B. After the cap is off, remove terminal 2 (Violet
wire) from the low beam headlight connector
wire using the Terminal Removing Tool “F”.

Figure 3.

SST P/N: 09991-00510

(1) After the terminal cap is removed, gently
insert the Terminal Removing Tool “F”
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.
NOTICE
When inserting the Terminal Removing
Tool “F”, pry carefully outward just
enough to remove the terminal from
the wire side. Excessive pressure may
damage the lock, or bend the tool.

1

(2) As the lock is held outward, gently tug
on the Violet wire from the back of the
connector to remove it.
1

C. Insert the terminal of Engine Wire No. 4
(White-Black) in headlamp bulb No. 2
connector.

Terminal Lock

Figure 4.