DISTRIBUTE TO: No.: POL16-02
eee eel HP TOYOTA Date: 519/16
Warranty Administrator *

Page: 1of5

Warranty Policy Bulletin

SUBJECT: WARRANTY ENHANCEMENT PROGRAM (ZF5):
WARRANTY EXTENSION FOR HYBRID INVERTER
ASSEMBLY ON CERTAIN 2012-2014 MY PRIUS V
VEHICLES

Background

Toyota has received some reports indicating the Intelligent Power Module (IPM)
located inside the inverter assembly of the hybrid system may fail. This condition
is indicated by the hybrid system diagnostic trouble codes (DTCs): POA94,
P324E, P3004, and/or POA1A. If one or more of these DTCs are detected,
various warning lamps on the instrument panel will illuminate and the vehicle will
enter fail safe mode.

Applicability

The hybrid inverter assembly is covered under the Toyota New Vehicle Limited
Warranty for 8 years from the date of first use or 100,000 miles (whichever
occurs first). However, Toyota is announcing a Warranty Enhancement Program
to cover repairs related to the condition described above.

This Warranty Enhancement Program provides an extension to the Toyota New
Vehicle Limited Warranty for repairs related to certain internal malfunctions of the
IPM. The vehicles covered under this warranty enhancement must first have
Safety Recall FOR performed (if applicable). This warranty enhancement covers

failure of the IPM and other internal inverter components potentially damaged by
IPM failure. If the condition is verified, an appropriate remedy will be performed
under the terms of this Warranty Enhancement Program.

This warranty enhancement provides coverage for 15 years, regardless of
mileage.

Verify VIN applicability for this warranty enhancement by checking TIS before
completing any repairs.

Toyota Warranty Policy Bulletin POL16-02
519/16
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Applicability (Continued

Direct marketing of this warranty enhancement is strictly prohibited pursuant to
the Toyota Warranty Policy 5.21, “Warranty Solicitation.”. Non-compliance with
this policy may result in a claim debit.

This Warranty Enhancement Program is subject to all of the terms and
conditions set forth in the Toyota New Vehicle Limited Warranty. For
example, damage from abuse, an accident, theft and/or vandalism is not
covered by the New Vehicle Limited Warranty or this Warranty
Enhancement.

Technician Training Requirements

The repair quality of covered vehicles is extremely important to Toyota. All
dealership technicians performing this repair are required to successfully
complete the most current version of the E-Learning course “Safety Recall and
Service Campaign Essentials”. To ensure that all vehicles have the repair
performed correctly; technicians performing this repair are required to currently
hold at least one of the following certification levels:

e Hybrid Expert Technician
« Master Technician
¢ Master Diagnostic Technician (MDT)

Always check which technicians can perform the recall remedy by logging on to
https://www.uotdealerreports.com. It is the dealership's responsibility to select
technicians with the above certification level or greater to perform this repair.
Carefully review your resources, the technician skill level, and ability before
assigning technicians to this repair. {t is important to consider technician days off
and vacation schedules to ensure there are properly trained technicians available
to perform this repair at all times. Claims for repairs that were performed by non-
qualified technicians are subject to debit.

Toyota Warranty Policy Bulletin POL16-02
5/19/16
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Claim Submission
Claim Opcode Description Labor Time
Typel | see e
BHG20A Replace the IPM Transistor 2.9 hr/vehicle
Replace the IPM Transistor
BHG20B + 2.9 hr./vehicle
Replace the MG ECU
Replace the IPM Transistor
+
BHG20C a 3.2 hrJvehicle
. Replace the inverter current sensor sub-
Pisa assembly
9 Replace the IPM Transistor
+
Replace the MG ECU
+ .
BC ECD Replace the inverter current sensor sub- Cee
assembly
+
Replace the inverter wire sub-assembly
BHG20E Replace the Inverter Assembly 1.6 hr.vehicle

* The cost Super Long Life Coolant (SLLC) may be claimed, at a maximum of $15.00
per vehicle, as Sublet Type “OF” under all opcodes listed above.

Note: If the vehicle is still under the New Vehicle Limited Warranty, submit the
repair as a Regular warranty claim.

Toyota Warranty Policy Bulletin

Replacement Parts

POL16-02
5/19/16
40f5

All parts replaced for this repair are subject to warranty parts recovery.

Opcode Part Number! Description Quantity
04899-47021 IPM Transistor Kit 1
04899-47060 Plug Kit / Inverter Drain 1
BHG20A 08887-02809 Thermal Grease 2
08826-00100 Seat Packing 1
90430-18008 Gasket 1
G920H-47040 MG ECU 41
[ 04899-47021 IPM Transistor Kit 1
\ 04899-47060 Plug Kit/ Inverter Drain 1
eich) 08887-02809 Thermal Grease 2
08826-00100 Seal Packing 1
90430-18008 Gasket 1
G920J-52010 Inverter Current Sensor 1
G920H-47040 MG ECU 1
04899-47021 IPM Transistor Kit 1
BHG20C 04899-47060 Plug Kit / Inverter Drain 1
08887-02809 Thermal Grease 2
08826-00100 Seal Packing 1
90430-18008 Gasket 1
G9208-47090 Inverter Wire Sub Assembly 1
G920J-52010 Inverter Current Sensor 1
G920H-47040 MG ECU 1
04899-47021 (PM Transistor Kit 1
BTICZOD) 04899-47060 Plug Kit / Inverter Drain 1
08887-02809 Thermal Grease 2
08826-00100 Seal Packing 1
90430-18008 Gasket 1
BHG20E G9200-49056 Inverter Assembly w/ Converter 4

Parts Ordering Process - Excludes SET and GST dealers

Due to portentially limited availability, the parts may have been placed on either
Manual Allocation Control (MAC) or Deaier Ordering Solutions (DOS). As the
parts inventory improves, the ordering process may change. Please check the
Toyota Special Activities MAC/DOS report on Dealer Daily for the most up-to-

date parts ordering information.

Technical Instructions (Re;

ir Procedures

Technical instructions can be found in T-SB-0036-16, please refer to TIS for

additional information.

Toyota Warranty Policy Bulletin POL16-02
5/19/16
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Customer-Paid Repairs or Replacement of Components

If a customer has previously paid for the repair to address the condition
described above, please have them mail a copy of the repair order, proof-of-
payment, and ownership information to the following address for reimbursement
consideration:

Toyota Motor Sales, U.S.A., Inc.
Customer Experience Center, WC10
19001 South Western Avenue
Torrance, CA 90509

The customer name, address, and telephone number(s) should be included in
the request. The customer should allow 4-6 weeks for processing.