T-SB-01 28-15 December 23, 2015 CY) TOYOTA

Technical Service Bulletin

2016 Prius Pre-Delivery Service (PDS)

Service
Category General
Toyota Supports
Section Pre-Delivery Service Market USA ASE Certification
Applicability
YEAR(S) MODEL(S) ADDITIONAL INFORMATION
2016 Prius

Introduction

Pre-Delivery Service (PDS) is a critical step in satisfying your new car customers. Customer
feedback indicates the following areas deserve special attention when performing PDS:

« Careful inspection for paint chips/scratches and body dents/dings.

* Proper operation of electrical accessories (including interior light, clock, and radio reset).
e Interior cleanliness.

* Proper function of mechanical systems.

Customer retention and proper maintenance of vehicles has been a major focus for Toyota. To
help remind customers that regular oil changes are essential to the proper maintenance of their

vehicle, dealers are required to begin installing a first oil change reminder sticker prior to delivery.
By doing this, customers will be reminded to return to your dealership for their first oil change.
Your current oil change reminder sticker may be used. (See PDS Check Sheet item 8 of “Final
Inspection & Cleaning.”)

Anew PDS Check Sheet has been developed for the 2016 model year Prius. Some check points
have been added, expanded, or clarified. Bulletins are available for items in bold type.

Precaution

The Prius has unique operating modes, so always follow the precautions below when performing
the PDS operation:

¢ The Prius contains high-voltage (200 ~ 650 volts) AC and DC systems. All high-voltage wiring

and connections are orange in color. Do NOT carelessly touch these orange-colored wiring
harnesses and connectors.

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2016 Prius Pre-Delivery Service (PDS)

Precaution (Continued)

The gasoline engine may start up and shut down suddenly whenever the “READY” light is
illuminated. Be sure to press the “P” position switch, apply the parking brake, press the
“POWER?” switch in order to stop the hybrid system (the “READY” light is OFF), and
remove the ignition key before working in the engine compartment.

The hybrid transaxle, engine radiator, and inverter radiator may reach high temperatures
during inspection. Carefully observe all caution labels and instructions on these components.

Be sure to place the shift selector into “P” (press the “P” switch) at all times unless otherwise
instructed. When the shift selector is in the “N” position, the hybrid vehicle battery will NOT
charge even if the gasoline engine is operating.

When leaving the vehicle, press the “P” position switch, apply the parking brake, and press
the “POWER” switch in order to stop the hybrid system (the “READY” light is OFF). Remove
the ignition key.

Air vents are provided on the package tray behind the rear seatback to coo! the hybrid vehicle
battery. Do NOT block these air vents

Do NOT splash water on the electric components in the engine compartment.

Warranty Information

OP CODE DESCRIPTION TIME OFP T™1 «| «OT2
001013 Pre-Delivery Service (PDS) a a -
Warranty Policy

If the need for additional repairs or adjustment is noted during PDS, the required service should be
performed under warranty. Reimbursement will be managed under the warranty policy.

The Warranty Policy and Procedures Manual requires that you maintain the completed Prius
PDS Check Sheet in the customer’s file, If you cannot produce a completed form for each retailed
vehicle upon TMS and/or Region/Distributor audit, the PDS payment amount will be subject to debit.

An additional Repair Order completed in conjunction with normal PDS must have time punch/flags
for service. If multiple repairs are performed, separate time flags must be punched for each repair.

© 2015 Toyota Motor Sales, USA
CP TOYOTA T-SB-0128-15 December 23, 2015 Page 3 of 7

2016 Prius Pre-Delivery Service (PDS)

Required Tools & Equipment

REQUIRED EQUIPMENT SUPPLIER PART NUMBER arty
Techstream 2.0* TS2UNIT
ADE 1
Techstream Lite TSLITEPDLRO1

* Essential SST.

NOTE

«® Only ONE of the Techstream units listed above is required.

« Software version 10.30.029 or later is required.

* Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE)

at 1-800-368-6787.

Before Inspection

1
2.

Install Short Pin — see check sheet
Install radio antenna’®

Functional Operation

Apply parking brake and cycle ignition “IG-ON,” place gear selector in reverse, turn on lights and
rear defogger. Unlock all doors, release fuel door.

1

. Check dome, courtesy, map, and sun visor lights*
2. Check warning/indicator lights, gauges, and horn
3. Check windshieid wipers and washers

4,
5
6

Check headlights, instrument lights, turn signals, emergency flashers, and brake lights

. Check inside/outside rear view mirror operation/adjustment

. Check cigarette lighter* and power outlets

Check the power outlet using an electrical accessory designed for this use.

. Check audio/navigation*/backup camera* systems and set clock

For navigation, set the destination search area to local position.

. Verify Entune/Navigation software version (Display Audio, Non-HDD Type only)* —

JT-SB-0163-13

. Check multi-information display and trip information on center display”

© 2015 Toyota Motor Sales, USA

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2016 Prius Pre-Delivery Service (PDS)

Functional Operation (Continued)

10. Install shift-lock override button cover*

11. Check sliding roof*

Walkaround Inspection

Starting at the left front door, check window and door lock operation and the operation of all power

windows and door locks from master switch, on vehicles so equipped. While walking around vehicle
in a counterclockwise direction, open left rear door (if applicable) and check operation of window
regulator and door lock, set child safety door locks to the normal (unlocked) position. Assure
tightness of interior garnishes and check seat belts. Inspect lights at rear of vehicle. Repeat checks
at right rear door. Inspect right front door window regulator and lock operation and garnishes. Check
seats and seat belt operation. Continue on around to the front of the vehicle checking lights.

. Check Smart Key system — T-SB-0024-14

. Check window operation

. Check that engine starts with all keys

. Check that child safety door locks are in normal (unlocked) position*
. Check seats and seat belt operation

. Check rear defogger/rear view mirror defogger

. Check side marker, tail, backup, and license plate lights

. Check luggage compartment fight* and trim appearance

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. Adjust spare tire pressure, inspect for damage, and check jack and tool installation
NOTE
Compact spare tire - 60 psi (420kPa).

10. Check headlight aim
Refer to the Repair Manual for procedures.
11. Check battery state-of-charge using Digital Battery System Analyzer

Refer to Service Bulletin No. PGO01-06, “Battery Maintenance for In-Stock Vehicles &
Pre-Delivery.”

NOTE

Battery SOC should be a minimum of 75%. Please enter the SOC Reading on the space
provided on the check sheet and attach the printout to the check sheet.

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2016 Prius Pre-Delivery Service (PDS)

Under Hood
1. Check engine oil level
2. Check brake fluid level
Visually inspect using see-through reservoirs.
Check engine coolant level
Check inverter coolant level

Check windshield washer fluid level

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Inspect for fuel, oil, coolant, and other fluid leaks

Battery Maintenance
1. Perform HV battery check and maintenance — T-SB-0087-14

Under Vehicle (On Hoist)
1. Remove disc brake anti-rust covers/anti-corrosion wheel film* — PD017-04

Visually inspect rotors for rust.

NOTE
For best rotor rust prevention, retain whee! film on vehicle until just prior to customer delivery.

. Inspect tires for defects/damage

. Activate and Initialize Tire Pressure Warning System (TPWS) — see check sheet
. Install wheel caps*

. Install front spoiler under cover and side spoilers — T-SB-0080-14

. Inspect for fuel, oil, coolant, and other fluid leaks

. Inspect under the vehicle for damage, rust etc.

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. Visually check bolts and nuts on chassis and powertrain for looseness
9. Install rubber body plugs (stored in glove box or console)*

10. Check hybrid transaxle fluid level

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2016 Prius Pre-Delivery Service (PDS)

Road Test

A complete road test helps assure customer satisfaction. Drive vehicle over a variety of road

surfaces and driving conditions. Check for unusual noise and driving performance.

1.Check cold engine operation

Check starting and fast idle operation performance.

. Check engine operation during warm-up

Check that engine operates smoothly during warm-up.

Check for unusual noise, engine vibration, rough idle, etc.

. Check engine at normal operating temperature

Check engine performance over a broad range of driving conditions, including idle quality,
acceleration, cruise, and deceleration.

. Check hybrid transaxle operation

. Check brake and parking brake operation

Check brake function, including unusual noise, parking brake performance, and all related
brake system indicator lights.

. Check steering operation and off-center/vehicle pull/flutter

Check steering function.

Check steering off-center/vehicle pull/flutter.

7. Inspect for abnormal noise and vibration

8. Inspect for squeaks and rattles

9. Check front and rear* heater and A/C operation

10.

11.

Check cruise control operation*

Check cruise control, including On-Off switch, “SET/COAST,” “RESUME/ACCEL.,” and
“CANCEL” functions.

Check front seat heater/ventilation operation”

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2016 Prius Pre-Delivery Service (PDS)

Final Inspection & Cleaning

1.

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10.
11.
12.

Remove interior protective covers, unnecessary labels, tags, etc. (Remove protective covers
just before delivery to customer.)

Remove plastic covers from door panels, seats, head restraints, and sun visors, as required.

Remove labels, tags, and stickers (except those containing owner information).

NOTE

Customer information labels, such as the fuel caution, airbag warnings, and bumper labels,
MUST be left on the vehicle until delivery to a retail customer.

. Visually inspect all interior parts for installation, damage, fit, dirt, ete.
. Verify floor mat application and install using retaining clips* — T-SB-0029-14
. Verify green light ts illuminated on SOS (Safety Connect) button*

NOTE

Vehicle may arrive with hanger requesting inspection to Safety Connect system. If system is
working properly and green light is illuminated, disregard hanger.

. Remove Rapgard™ and clear protective bumper film*

Ensure that ALL glue residue is removed.

. Wash and clean vehicle
. Inspect paint finish for scratches, chips, rust, dents, damage, etc.
. Inspect exterior body parts for proper installation, damage, rust, etc.

. Place oil change sticker on inside of windshield, top left corner

Complete the mileage or date recommendation and apply the oil change reminder sticker to the
inside of the windshield, top left corner. You may use your current oil change reminder sticker.

Install front license plate and mounting bracket* — see check sheet
Piace Owner's Guide and first aid kit portfolio* in glove box
Perform Techstream Health Check

Perform Health Check to ensure that diagnostic trouble codes are not present. Health Check
results can be printed for the customer at delivery, or for the dealer file, using the Diagnostic
Report function.

* Inspect or install when equipped or required

© 2015 Toyota Motor Sales, USA