Vehicle report

2002 TOYOTA PRIUS

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Service bulletins

106 bulletins

Technical service bulletins are instructions a manufacturer sent its dealers about a known fault. They are not recalls and the work is usually not free, but they are the clearest signal of a problem the manufacturer already knows about.

T-SB-0009-26

Service Bulletin/Repair Instructions

This bulletin includes basic procedures for performing a rescue charge on Ni-MH high voltage (HV) batteries. This bulletin should be used in conjunction with the applicable model and model year Repair Manual while performing a rescue charge. The GRX-5100 should be used wherever the Repair Manual references the Toyota Hybrid System (THS) charger.

T-SB-0119-15 Rev2

Service Bulletin/Repair Instructions

OBSOLETE NOTICE February 13, 2026: This bulletin is now obsolete. Please see T-SB-0009-26.

T-SB-0035-24 Rev2

Service Bulletin/Repair Instructions

Acid rain results from rainwater or other airborne moisture that become acidic due to industrial chemical impurities in the atmosphere. If these acidic compounds settle on an exposed vehicle, especially the horizontal areas such as the hood, roof, and decklid, significant damage to the painted surfaces can occur. Acid rain damage can typically be identified on vehicles by the presence of stains on the paint surface that resemble hard water spots. Unlike water spots however, acid rain damage cannot be removed by regular washing procedures. Also, because acid rain can etch and soften the paint, normal buffing or polishing repair procedures should not be attempted. This can cause further damage and result in visible depressions in the paint surface. The following are the three major categories of acid rain damage: •Minor damage: requires only buffing to repair. •Moderate damage: usually requires neutralizing, color sanding, and buffing. •Severe damage: extending beyond 1/2 mil of clearcoat on a pearl, metallic, or solid color, requires neutralization, sanding, and repainting. In cases where acid rain damage is minor, neutralization and buffing with a liquid-type paint finessing product may provide an adequate repair. Only specially formulated products outlined in this bulletin should be used for that purpose. Unfortunately, other than minor damage, there is no simple method of determining the actual extent (depth) of acid penetration other than color sanding a representative affected area until there is no visible etching or depressions, followed by measuring the amount of paint removed with either a magnetic or digital-type film thickness gauge. The procedures in this bulletin are intended for use by qualified body/paint technicians and should not be attempted by inexperienced personnel. It is the dealer’s responsibility to protect and maintain the quality of the vehicle’s paint finish after receipt at the dealership prior to the first sale. Perform frequent vehicle washing, as often as daily, during high heat and humidity periods to minimize the potential for paint damage due to acid rain exposure. This is especially important in geographical areas known for high frequency and concentration of acid rain and industrial fallout.

T-SB-0038-24 Rev2

Service Bulletin/Repair Instructions

To prevent brake rotor rust from forming during transportation and storage, wheel film will be used instead of a cardboard type of anti-rust cover. The purpose of the wheel film is to shield the disc brake rotor from weather elements and initial rust before the vehicle is delivered to the customer. Consequently, the film should remain on the wheel for as long as possible.

T-SB-0039-24 Rev2

Service Bulletin/Repair Instructions

The condition known as acid rain is caused by airborne chemicals or particles in the atmosphere, which mix with rainwater, nighttime dew, or high humidity to form acidic compounds. If these contaminants settle and remain on a painted vehicle surface, especially the horizonal areas of the hood, roof, and decklid, significant damage can occur. This damage is the result of actual etching of the paint and appears as pitting or water spots. As acid rain droplets on the vehicle surface evaporate, the concentration strength of the acid increases, causing deeper and more rapid damage. This evaporation and corrosive action also occur more rapidly on dark colored cars as direct sun heat increases. It is the dealer’s responsibility to protect and maintain the quality of the vehicle’s paint finish after receipt at the dealership prior to the first sale. In areas known for high frequency and/or concentration of acid rain, frequent vehicle washing during high heat or humidity periods will minimize the potential for paint damage caused by acid rain. It is further recommended that either reverse osmosis or deionized water be used to prevent water spotting.

T-SB-0061-23 Rev2

Service Bulletin/Repair Instructions

Toyota vehicles are currently protected with RapgardTM protective film designed to protect the horizontal painted surfaces. This material protects from acid rain, environmental fallout, and rail contamination. Follow the Removal Procedure in this bulletin to remove the RapgardTM protective film within 90 days from initial application.

T-SB-0062-23 Rev2

Service Bulletin/Repair Instructions

Vehicles may occasionally be subjected to contamination by airborne iron particles shed from railroad tracks, train wheels, exposure to heavy machinery facilities, grinding, welding, etc. This type of contamination can be identified by the presence of small, red or brown particles on the paint surface. These particles are often difficult to see on dark color paints but can be easily felt when brushing a hand across horizontal body surfaces such as the hood, roof, or deck lid. Follow the Repair Procedure in this bulletin to clean vehicles that may have been subjected to contamination by airborne iron particles such as rail dust during rail transportation or extended storage near industrial areas.

T-SB-0035-24 Rev1

Service Bulletin/Repair Instructions

Acid rain results from rainwater or other airborne moisture that become acidic due to industrial chemical impurities in the atmosphere. If these acidic compounds settle on an exposed vehicle, especially the horizontal areas such as the hood, roof, and decklid, significant damage to the painted surfaces can occur. Acid rain damage can typically be identified on vehicles by the presence of stains on the paint surface that resemble hard water spots. Unlike water spots however, acid rain damage cannot be removed by regular washing procedures. Also, because acid rain can etch and soften the paint, normal buffing or polishing repair procedures should not be attempted. This can cause further damage and result in visible depressions in the paint surface. The following are the three major categories of acid rain damage: •Minor damage: requires only buffing to repair. •Moderate damage: usually requires neutralizing, color sanding, and buffing. •Severe damage: extending beyond 1/2 mil of clearcoat on a pearl, metallic, or solid color, requires neutralization, sanding, and repainting. In cases where acid rain damage is minor, neutralization and buffing with a liquid-type paint finessing product may provide an adequate repair. Only specially formulated products outlined in this bulletin should be used for that purpose. Unfortunately, other than minor damage, there is no simple method of determining the actual extent (depth) of acid penetration other than color sanding a representative affected area until there is no visible etching or depressions, followed by measuring the amount of paint removed with either a magnetic or digital-type film thickness gauge. The procedures in this bulletin are intended for use by qualified body/paint technicians and should not be attempted by inexperienced personnel. It is the dealer’s responsibility to protect and maintain the quality of the vehicle’s paint finish after receipt at the dealership prior to the first sale. Perform frequent vehicle washing, as often as daily, during high heat and humidity periods to minimize the potential for paint damage due to acid rain exposure. This is especially important in geographical areas known for high frequency and concentration of acid rain and industrial fallout.

T-SB-0038-24 Rev1

Service Bulletin/Repair Instructions

To prevent brake rotor rust from forming during transportation and storage, wheel film will be used instead of a cardboard type of anti-rust cover. The purpose of the wheel film is to shield the disc brake rotor from weather elements and initial rust before the vehicle is delivered to the customer. Consequently, the film should remain on the wheel for as long as possible.

T-SB-0039-24 Rev1

Service Bulletin/Repair Instructions

The condition known as acid rain is caused by airborne chemicals or particles in the atmosphere, which mix with rainwater, nighttime dew, or high humidity to form acidic compounds. If these contaminants settle and remain on a painted vehicle surface, especially the horizonal areas of the hood, roof, and decklid, significant damage can occur. This damage is the result of actual etching of the paint and appears as pitting or water spots. As acid rain droplets on the vehicle surface evaporate, the concentration strength of the acid increases, causing deeper and more rapid damage. This evaporation and corrosive action also occur more rapidly on dark colored cars as direct sun heat increases. It is the dealer’s responsibility to protect and maintain the quality of the vehicle’s paint finish after receipt at the dealership prior to the first sale. In areas known for high frequency and/or concentration of acid rain (see Figure 1), frequent vehicle washing during high heat or humidity periods will minimize the potential for paint damage caused by acid rain. It is further recommended that either reverse osmosis or deionized water be used to prevent water spotting.

T-SB-0061-23 Rev1

Service Bulletin/Repair Instructions

Toyota vehicles are currently protected with RapgardTM protective film designed to protect the horizontal painted surfaces. This material protects from acid rain, environmental fallout, and rail contamination.

T-SB-0062-23 Rev1

Service Bulletin/Repair Instructions

Vehicles may occasionally be subjected to contamination by airborne iron particles shed from railroad tracks, train wheels, exposure to heavy machinery facilities, grinding, welding, etc. This type of contamination can be identified by the presence of small, red or brown particles on the paint surface. These particles are often difficult to see on dark color paints but can be easily felt when brushing a hand across horizontal body surfaces such as the hood, roof, or deck lid.

T-SB-0035-24

Service Bulletin/Repair Instructions

Acid rain results from rainwater or other airborne moisture that become acidic due to industrial chemical impurities in the atmosphere. If these acidic compounds settle on an exposed vehicle, especially the horizontal areas such as the hood, roof, and decklid, significant damage to the painted surfaces can occur. Acid rain damage can typically be identified on vehicles by the presence of stains on the paint surface that resemble hard water spots. Unlike water spots however, acid rain damage cannot be removed by regular washing procedures. Also, because acid rain can etch and soften the paint, normal buffing or polishing repair procedures should not be attempted. This can cause further damage and result in visible depressions in the paint surface. The following are the three major categories of acid rain damage: •Minor damage: requires only buffing to repair. •Moderate damage: usually requires neutralizing, color sanding, and buffing. •Severe damage: extending beyond 1/2 mil of clearcoat on a pearl, metallic, or solid color, requires neutralization, sanding, and repainting. In cases where acid rain damage is minor, neutralization and buffing with a liquid-type paint finessing product may provide an adequate repair. Only specially formulated products outlined in this bulletin should be used for that purpose. Unfortunately, other than minor damage, there is no simple method of determining the actual extent (depth) of acid penetration other than color sanding a representative affected area until there is no visible etching or depressions, followed by measuring the amount of paint removed with either a magnetic or digital-type film thickness gauge. The procedures in this bulletin are intended for use by qualified body/paint technicians and should not be attempted by inexperienced personnel. While the quality and durability of paint on Toyota vehicles is continuously being improved, it remains the dealer’s responsibility to protect and maintain the quality of the vehicle’s paint finish after receipt at the dealership prior to the first sale. To read, While the quality and durability of paint on Toyota vehicles is continuously being improved, it remains the dealer’s responsibility to protect and maintain the quality of the vehicle’s paint finish after receipt at the dealership prior to first sale. Perform frequent vehicle washing, as often as daily, during high heat and humidity periods to minimize the potential for paint damage due to acid rain exposure. This is especially important in geographical areas known for high frequency and concentration of acid rain and industrial fallout.

T-SB-0038-24

Service Bulletin/Repair Instructions

To prevent brake rotor rust from forming during transportation and storage, wheel film will be used instead of a cardboard type of anti-rust cover. The purpose of the wheel film is to shield the disc brake rotor from weather elements and initial rust before the vehicle is delivered to the customer. Consequently, the film should remain on the wheel for as long as possible. SUPERSESSION NOTICE The information contained in this bulletin supersedes Service Bulletin No. PD017-04. •The entire bulletin has been updated.

T-SB-0039-24

Service Bulletin/Repair Instructions

The condition known as acid rain is caused by airborne chemicals or particles in the atmosphere, which mix with rainwater, nighttime dew, or high humidity to form acidic compounds. If these contaminants settle and remain on a painted vehicle surface, especially the horizonal areas of the hood, roof, and decklid, significant damage can occur. This damage is the result of actual etching of the paint and appears as pitting or water spots. As acid rain droplets on the vehicle surface evaporate, the concentration strength of the acid increases, causing deeper and more rapid damage. This evaporation and corrosive action also occur more rapidly on dark colored cars as direct sun heat increases. While Toyota paint quality, durability, and resistance to environmental factors is continuously being improved, it remains the responsibility of the dealer to protect and maintain the vehicle’s paint finish from the time of arrival at the dealership until retail delivery to the customer. In areas known for high frequency and/or concentration of acid rain (see Figure 1), frequent vehicle washing during high heat or humidity periods will minimize the potential for paint damage caused by acid rain. It is further recommended that either reverse osmosis or deionized water be used to prevent water spotting.

T-PANT-2024-004-

Service Bulletin/Repair Instructions

This is to advise of various price adjustments that will affect Toyota Genuine Motor Oil and Long Life Coolant, effective March 1, 2024. These products are ordered through the Toyota Complete Maintenance Care (TCMC) website.

T-SB-0043-14

Service Bulletin/Repair Instructions

OBSOLETE NOTICE January 22, 2024: This bulletin is now obsolete. Please see T-SB-0057-18.

TSB003220

Service Bulletin/Repair Instructions

TSB: Replacement certification labels (the vinyl label installed on the driver door or door post) and VIN plates (the metal plate riveted to dashboard) (see Figure 1) for most 1979 ? 2023 model year vehicles may be available provided the requests meet the criteria listed in this Service Bulletin. Follow the Procurement Procedure in this bulletin to request a replacement certification label or VIN plate.

T-SB-0057-18

Service Bulletin/Repair Instructions

TSB: The Immobilizer and Smart Key Reset is a feature that allows the registration of new keys when all master keys are lost. Once the system is reset, all previously registered keys will be erased. Follow the procedures in this bulletin to reset a vehicle Immobilizer or Smart Key system.

T-SB-0119-15 Rev

Service Bulletin/Repair Instructions

TSB: This bulletin includes basic procedures for performing a rescue charge on Ni-MH high voltage (HV) batteries. This bulletin should be used in conjunction with the applicable model and model year Repair Manual while performing a rescue charge. The GRX-5100 should be used wherever the Repair Manual references the Toyota Hybrid System (THS) charger

TTT063620

Service Bulletin/Repair Instructions

TT: Some Toyota vehicles installed with Toyota Complete Maintenance Care (TCMC) brake pads may exhibit a groan or squeak noise in various driving conditions

Toyota Safety Re

Service Bulletin/Repair Instructions

Toyota Safety Recall and Service Campaign - Technician Certification Requirements

T-TT-0636-20 Rev

Service Bulletin/Repair Instructions

TT: Some Toyota vehicles installed with Toyota Complete Maintenance Care (TCMC) brake pads may exhibit a groan or squeak noise in various driving conditions.

T-SB-0032-20 Rev

Service Bulletin/Repair Instructions

TSB: Replacement certification labels (the vinyl label installed on the driver door or door post) and VIN plates (the metal plate riveted to dashboard) (see Figure 1) for most 1979 ? 2021 model year vehicles may be available provided the requests meet the criteria listed in this Service Bulletin. Follow the Procurement Procedure in this bulletin to request a replacement certification label or VIN plate.

T-TT-0636-20

Service Bulletin/Repair Instructions

TT: Some Toyota vehicles installed with Toyota Complete Maintenance Care (TCMC) brake pads may exhibit a groan or squeak noise in various driving conditions.

T-SB-0063-20

Service Bulletin/Repair Instructions

TSB: SUPERSESSION NOTICE The information contained in this bulletin supersedes Service Bulletin Nos. ST005-01, SU001-08, and T-SB-0391-08. The aforementioned bulletins are obsolete, and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. This Service Bulletin provides best practice procedures for vehicle pulling complaint, diagnosis, and repair for 2002 ? 2021 model year Toyota vehicles. This information supplements Repair Manual procedures when the symptoms are: ?Vehicle Pulling: The vehicle moves to the right or left when the driver holds the steering wheel while driving straight ahead without exerting steering effort. ?Steering Wheel Off Center: The vehicle travels straight, but the steering wheel is not pointed straight ahead. The vehicle is not pulling. Before repairing a vehicle pulling to one side, it is necessary to clearly identify the cause of the pulling condition. Frequently, pulling to one side is diagnosed as a wheel alignment concern. However, the actual cause may be related to the lateral force generated by the tires, vehicle damage, road crown or worn components. Performing a wheel alignment when tire force is the cause could result in the wheel alignment being set at a value outside of specifications. This could then cause other problems such as uneven tire wear, etc. A customer may notice a pull to the left when in the left lanes of travel and notice a pull to the right or no pull when traveling in the right lanes of travel on the very same section of roadway. This road crown effect is environmental and cannot be corrected with suspension adjustments or any other wheel or tire modification discussed in this bulletin.

T-SB-0391-08 Obs

Service Bulletin/Repair Instructions

TSB: OBSOLETE NOTICE June 23, 2020: This bulletin is now obsolete. Please see T-SB-0063-20.

T-SB-0119-15_Rev

Service Bulletin/Repair Instructions

TT: This bulletin includes basic procedures for performing a rescue charge on Ni-MH high voltage (HV) batteries. This bulletin should be used in conjunction with the applicable model and model year Repair Manual while performing a rescue charge. The GRX-5100 should be used wherever the Repair Manual references the Toyota Hybrid System (THS) charger.

T-SB-0304-17 Obs

Service Bulletin/Repair Instructions

TSB: OBSOLETE NOTICE April 07, 2020: This bulletin is now obsolete. Please see T-SB-0032-20. Replacement Certification Labels and VIN Plates

T-SB-0032-20

Service Bulletin/Repair Instructions

TSB: SUPERSESSION NOTICE The information contained in this bulletin supersedes Service Bulletin Nos. PG021-88, PG015-89, PG0015-90, PG002-91, PG002-93, PG005-97, PG007-01, PG007-07, PG006-01, PG004-97, T-SB-0144-08, and T-SB-0304-17. The aforementioned bulletins are obsolete, and any printed versions should be discarded. Replacement certification labels (the vinyl label installed on the driver door or door post) and VIN plates (the metal plate riveted to dashboard) (see Figure 1) for most 1979 ? 2020 model year vehicles may be available provided the requests meet the criteria listed in this Service Bulletin. Follow the Procurement Procedure in this bulletin to request a replacement certification label or VIN plate.

T-SB-0008-20

Service Bulletin/Repair Instructions

TSB: Vehicles may display evidence of a fluid leak or fluid seep from powertrain components. This bulletin explains how to determine the differences between a fluid leak versus a fluid seep. Cases that are determined to be a ?leak? should be repaired accordingly and will be covered under warranty if applicable. Cases that are determined to be a ?seep? should be documented on the repair order and inspected at the next service interval. Follow the Repair Information in this bulletin to determine if the concern in question is a fluid leak or fluid seep and review the Repair Procedure section to address the condition. NOTE This bulletin applies to ALL powertrain fluids excluding fuel and coolant.

ZTI_Dealer Packa

Service Bulletin/Repair Instructions

Dealer Package: 09/30/19 A watermark has been added to the Dealer Letter to indicate that ZTI expired on September 30, 2019. In our continuing efforts to assure the best in customer satisfaction, Toyota will initiate a Customer Support Program (CSP) to extend the warranty coverage on specific Malfunction Indicator Light (MIL) ?ON? Diagnostic Code for certain 2001 through 2003 model year Prius vehicles. Toyota has received reports that certain 2001 through 2003 model year Prius vehicles may exhibit a MIL (check engine light) ?ON? with the following codes: ? Diagnostic codes P3190 and P3101 with information code 204 or ? Diagnostic codes P3191 and P3101 with information code 205

T-SB-0134-16-Rev

Service Bulletin/Repair Instructions

TSB: REVISION NOTICE July 01, 2019 Rev2: ? Applicability has been updated to 2019 ? 2020 model year Toyota vehicles. ? The Techstream Preparation and Process Overview sections have been updated. October 30, 2017 Rev1: ? Applicability has been updated to include 2018 model year vehicles. Any previous printed versions of this bulletin should be discarded. SUPERSESSION NOTICE The information contained in this bulletin supersedes SB No. T-SB-0012-13. Service Bulletin No. T-SB-0012-13 is obsolete and any printed versions should be discarded. Be sure to review the entire content of this bulletin before proceeding. Flash reprogramming allows the Electronic Control Unit (ECU) software to be updated without replacing the ECU. Flash calibration updates for specific vehicle models/ECUs are released as field-fix procedures described in individual Service Bulletins. This bulletin details the Techstream ECU flash reprogramming process and outlines use of the Technical Information System (TIS) and the Calibration Update Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU?s information. NOTE ECU is a Toyota term used to describe integrated computerized devices responsible for managing the operation of a system or subsystem. For the purposes of this bulletin, the term ?ECU? is used as a generic label for the following SAE J1930 standard references: ? Powertrain Control Module (PCM) ? Engine Control Module (ECM) ? Transmission Control Module (TCM) ? Any other Toyota specific control unit

ZTP-Expired-Deal

Service Bulletin/Repair Instructions

Dealer Package: September 11, 2018 A watermark has been added to the Dealer Letter to indicate that ZTP expired on September 10, 2018. Toyota has received reports of customer concerns regarding an unusual steering wheel vibration when the driver releases the steering wheel in certain 2001 to 2003 model year Prius vehicles. Although the electronically-assisted power steering rack is covered by Toyota?s New Vehicle Limited Basic Warranty for 3 years or 36,000 miles, whichever comes first, we at Toyota care about the overall ownership experience with the Prius. To assure our customers that we stand behind our product, we are offering an extension of the warranty coverage on the vehicle?s electronically-assisted power steering rack. The following vital information is provided to inform you and your staff of the program notification schedule and your degree of involvement.

PG004-97-Obsolet

Service Bulletin/Repair Instructions

Technical Service Bulletin: OBSOLETE NOTICE: July 31, 2018: This bulletin is now obsolete. Please see T-SB-0304-17.

PG006-01-Obsolet

Service Bulletin/Repair Instructions

Technical Service Bulletin: OBSOLETE NOTICE: July 31, 2018: This bulletin is now obsolete. Please see T-SB-0304-17.

T-SB-0304-17_Rev

Service Bulletin/Repair Instructions

TSB: REVISION NOTICE July 31, 2018 Rev2: ? The Supersession Notice has been updated. January 11, 2018 Rev1: ? The Supersession Notice has been updated. Any previous printed versions of this bulletin should be discarded. SUPERSESSION NOTICE The information contained in this bulletin supersedes Service Bulletin Nos. PG021-88, PG015-89, PG0015-90, PG002-91, PG002-93, PG005-97, PG007-01, PG007-07, PG006-01, PG004-97, and T-SB-0144-08. Service Bulletin Nos. PG021-88, PG015-89, PG0015-90, PG002-91, PG002-93, PG005-97, PG007-01, PG007-07, PG006-01, PG004-97, and T-SB-0144-08 are obsolete and any printed versions should be discarded. Vehicle replacement certification labels (the vinyl label installed on the driver door or door post) and VIN plates (the metal plate riveted to dashboard) may be available from Toyota, provided the request meets one of the criteria listed in this Service Bulletin. Replacement Certification Label and VIN Plate Criteria A replacement certification label and/or VIN plate may be requested if: ? The vehicle was in an accident and the label and/or plate is damaged or attached to a part that will be replaced during the repair. ? The label and/or plate was stolen.

T-SB-0229-12_Rev

Service Bulletin/Repair Instructions

TSB: REVISION NOTICE November 22, 2017 Rev1: ? Applicability has been updated to include 2014 ? 2018 model year vehicles. Any previous printed versions of this bulletin should be discarded. In the event that a Toyota vehicle becomes submerged in water, many components may be physically damaged. Electrical and electronic components, including wiring harnesses, are particularly susceptible to corrosion and subsequent malfunction. Although any flooding can be damaging, salt water flooding elevates the potential for abnormal conditions and may increase risks due to its highly corrosive and conductive nature. Salt residue also continues to corrode and remain conductive even after a vehicle dries. This bulletin is intended to assist with safe handling and inspection of flood damaged vehicles and to provide basic guidance on likely needed repairs.

T-SB-0144-08_Obs

Service Bulletin/Repair Instructions

TSB: OBSOLETE NOTICE November 21, 2017: This bulletin is now obsolete. Please see T-SB-0304-17.

T-SB-0134-16_Rev

Service Bulletin/Repair Instructions

TSB: REVISION NOTICE October 30, 2017 Rev1: * Applicability has been updated to include 2018 model year vehicles. SUPERSESSION NOTICE The information contained in this bulletin supersedes SB No. T-SB-0012-13. Flash reprogramming allows the Electronic Control Unit (ECU) software to be updated without replacing the ECU. Flash calibration updates for specific vehicle models/ECUs are released as field-fix procedures described in individual Service Bulletins. This bulletin details the Techstream ECU flash reprogramming process and outlines use of the Technical Information System (TIS) and the Calibration Update Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU's information.

T-SB-0304-17

Service Bulletin/Repair Instructions

TSB: Vehicle replacement certification labels (the vinyl label installed on the driver door or door post) and VIN plates (the metal plate riveted to dashboard) may be available from Toyota, provided the request meets one of the criteria listed in this Service Bulletin.

T-SB-0218-17_Rev

Service Bulletin/Repair Instructions

TSB: REVISION NOTICE July 20, 2017 Rev1: Applicability has been updated to exclude 2007 ? 2017 model year Avanza vehicles. Some hazardous material treatment and handling regulations at the state and local level define the pre-disposal deployment of airbag and pre-tensioner assemblies as hazardous material treatment. Hazardous material treatment may require special training, certification or licensing in certain areas. TMS recommends that dealership personnel carefully review and follow ALL local and state regulations, and where necessary, contract with Environmental Protection Agency (EPA) Licensed Hazardous Waste Transportation and Disposal facilities.

T-TT-0365-15 Rev

Service Bulletin/Repair Instructions

TT: A vehicle may arrive to the dealer with a MIL ?ON? condition and P0A80 or P1AC000 stored in the memory. Some cases have been identified with internal modification done to the HV Battery. Modified or altered parts are not covered under warranty.

TSB018217

Service Bulletin/Repair Instructions

TSB: SUPERSESSION NOTICE The information contained in this bulletin supersedes SB No. T-SB-0101-11. Applicability has been updated to include 2016 ? 2017 model year vehicles. Service Bulletin No. T-SB-0101-11 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this bulletin before proceeding. When servicing interior electrical switches and components, please note the precautions in this bulletin to avoid damaging electrical components and switches. Many lubricants, cleaners, and automotive chemicals contain silicone or other compounds that may contaminate electrical contacts, and therefore increase electrical resistance and decrease switch performance. The use of any cleaners or fluids may increase the risk of further damage to electrical components.

T-SB-0012-13 Rev

Service Bulletin/Repair Instructions

TSB: OBSOLETE NOTICE: September 14, 2016: This bulletin is now obsolete. Please see T-SB-0134-16.

T-TT-0365-15

Service Bulletin/Repair Instructions

TT: A vehicle may arrive to the dealer with a MIL ?ON? condition and P0A80 stored in the memory. Some cases have been identified with internal modification done to the HV Battery. Modified or altered parts are not covered under warranty.

T-SB-0134-16

Service Bulletin/Repair Instructions

TSB: Supersession Notice. Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash calibration updates for specific vehicle models/ECUs are released as field-fix procedures described in individual Service Bulletins. This bulletin details the Techstream ECU flash reprogramming process and outlines use of the Technical Information System (TIS) and the Calibration Update Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU?s information.

Safety Recall an

Service Bulletin/Repair Instructions

Update on Technician Certification Requirements.

T-TT-0395-16

Service Bulletin/Repair Instructions

TT: HV Batteries have liquid filled cell modules, to prevent leakage from cells, it is very important to confirm the proper orientation mark of the DRC.

T-SB-0119-15

Service Bulletin/Repair Instructions

TSB: This bulletin includes basic procedures for performing a Rescue Charge on Ni-MH High Voltage (HV) Batteries. This bulletin should be used in conjunction with the Repair Manual while performing Rescue Charge. The GRX-5100 should be used wherever the Repair Manual references the Toyota Hybrid System (THS) Charger.

T-TT-0362-15

Service Bulletin/Repair Instructions

TT: The vehicle may be difficult to start or have an abnormally low or rough idle after the battery has been disconnected or power to the Engine ECM has been interrupted.

T-TT-0086-11

Service Bulletin/Repair Instructions

TechTip: Condition - The vehicle may be difficult to start or have an abnormally low or rough idle after the battery has been disconnected or power to the Engine ECM has been interrupted.

T-TT-0303-14

Service Bulletin/Repair Instructions

TechTip: When a DTC is detected by the HV Battery ECU, the HV Control ECU will automatically store a P3000, Information Code 123 ?HV Battery Control System Malfunction? DTC. The purpose of the P3000/123 is to capture the state of the Hybrid Control System when the HV Battery ECU DTC sets. It does not indicate a malfunction of the HV Control ECU.

T-SB-0043-14 Rev

Service Bulletin/Repair Instructions

TSB: The Immobilizer and Smart Key Reset is a feature that allows the registration of new keys when all master keys are lost. Once the system is reset, all previously registered keys will be erased. Follow the procedures in this bulletin to reset a vehicle Immobilizer or Smart Key system. NOTE: There are new security provisions required to obtain a Reset Pass-Code. It is critical that the instructions for this new process are reviewed BEFORE attempting to get a Pass-Code in the new system.

T-SB-0083-13 Rev

Service Bulletin/Repair Instructions

TSB: The procedure in this bulletin is a general guideline on how to properly diagnose the air conditioning system after a component failure. Refer to the applicable Repair Manual for vehicle specific repair procedures and parts.

T-SB-0101-11 Rev

Service Bulletin/Repair Instructions

TSB: When servicing interior electrical switches and components, please note the precautions in this bulletin to avoid damaging electrical components and switches. Many lubricants, cleaners, and automotive chemicals contain silicone or other compounds that may contaminate electrical contacts, and therefore increase electrical resistance and decrease switch performance. The use of any cleaners or fluids may increase the risk of further damage to electrical components.

T-SB-0012-13 REV

Service Bulletin/Repair Instructions

TSB: FLASH REPROGRAMMING ALLOWS THE ECU SOFTWARE TO BE UPDATED WITHOUT REPLACING THE ECU. FLASH CALIBRATION UPDATES FOR SPECIFIC VEHICLE MODELS/ECUS ARE RELEASED AS FIELD-FIX PROCEDURES DESCRIBED IN INDIVIDUAL SERVICE BULLETINS. THIS BULLETIN DETAILS THE TECHSTREAM ECU FLASH REPROGRAMMING PROCESS AND OUTLINES USE OF THE TECHNICAL INFORMATION SYSTEM (TIS) AND THE CALIBRATION UPDATE WIZARD (CUW). FLASH CALIBRATION UPDATES CAN ONLY BE APPLIED TO THE VEHICLE/ECU COMBINATION FOR WHICH THEY ARE INTENDED. ECUS HAVE INTERNAL SECURITY THAT WILL NOT ALLOW THEM TO BE PROGRAMMED WITH ANOTHER ECU’S INFORMATION.

TSB-0012-13 Rev2

Service Bulletin/Repair Instructions

TSB: Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash calibration updates for specific vehicle models/ECUs are released as field-fix procedures described in individual Service Bulletins. This bulletin details the Techstream ECU flash reprogramming process and outlines use of the Technical Information System (TIS) and the Calibration Update Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU?s information.

T-TT-0010-10 Rev

Service Bulletin/Repair Instructions

Tech Tip: Low battery voltage can contribute to a MIL "ON" condition for P0335 (Crankshaft Position Sensor Circuit) and/or P0340 (Camshaft Position Sensor Circuit) due to inconsistent rotational speed of the engine's crankshaft.

T-TT-0132-11

Service Bulletin/Repair Instructions

A key part to maintain the proper function and safe operation of the vehicle's braking system is to perform a visual inspection when installing brake pads, calipers, and discs. The following recommendations are intended to provide general tips for the inspection and/or installation of Toyota Complete Maintenance Care (TCMC) front brake pads and discs. Always refer to the model specific Repair manual and TIS publications for specific repair instructions.

T-TT-0213-13

Service Bulletin/Repair Instructions

Toyota vehicles are equipped with Supplemental Restraint Systems (SRS), including various airbags and in some models, seat belt pre-tensioners, to help reduce the risk of injury in a collision. If a customer expresses any concerns that the SRS airbags or pre-tensioner devices did not perform as expected (including an unintended deployment event), please follow the steps in the recommendations section below.

T-SB-0185-13

Service Bulletin/Repair Instructions

The following procedures are recommended during routine maintenance or in the event of a customer concern for wiper performance.

TS-BO030-01 Obso

Service Bulletin/Repair Instructions

This bulletin is now obsolete. Please see T-SB-0185-13.

T-SB-0122-11 Rev

Service Bulletin/Repair Instructions

Beginning in 1998, Toyota introduced side airbags as optional equipment. Toyota does NOT recommend replacement of original seat covers with non-Toyota leather or other seat cover materials on vehicles due to the following: Seat covers NOT recommended by Toyota may affect side airbag performance, in general or in part, during an accident. Modifications that negatively affect side airbag performance can result in severe occupant injuries. Seat covers are an integral part of this safety system. Replacing fabric seat covers with non-Toyota leather or other seat cover materials may compromise the effectiveness of this safety system. The design of the seat is complex, integrating safety and strength with comfort and luxury. Toyota strongly discourages modifying original equipment seats that have optional side airbags. Additionally, Toyota strongly advises against the installation or use of aftermarket seat covers, which could impair the performance of the side airbags in the event of an accident.

T-TT-0269-13

Service Bulletin/Repair Instructions

The appearance of spots in tempered glass (when viewed at certain angles) is the result of the heat treating and quick quenching process during manufacturing.

T-SB-0141-13

Service Bulletin/Repair Instructions

A new Special Service Tool (SST 09709-00002) has been introduced to aid in the inspection procedure for certain vehicles equipped with a floor pedal-type parking brake system. This bulletin references the correct method for installing the Brake Pedal Force Gauge. Refer to the appropriate Repair Manual for parking brake pedal travel inspection and adjustment specification.

TC13-019

Service Bulletin/Repair Instructions

SUMMARY TO BE PROVIDED ON A FUTURE DATE.

T-PG006-00 Obsol

Service Bulletin/Repair Instructions

This bulletin is now obsolete. Please see T-SB-0054-13.

T-SB-0054-13

Service Bulletin/Repair Instructions

California (CA), Federal (FED), and 50 State Certified emission control underhood labels (emission labels) may be obtained through your dealership?s Parts Department utilizing standard replacement parts ordering procedures. Follow the guidelines outlined in this bulletin to ensure proper label application.

T-TT-0118-11 Rev

Service Bulletin/Repair Instructions

Technicians should confirm the following key points to minimize the potential for future MIL "ON" concerns after HV battery replacement.

T-SB-0141-10 Rev

Service Bulletin/Repair Instructions

If a creak, tick, or rattle noise is heard at the top or bottom of the windshield, or at the top of the rear glass, the source of the noise may be the two stoppers bonded to the top of the windshield/rear glass, or the windshield retainers bonded to the lower edge of the windshield. This bulletin provides the recommended repair procedure to eliminate these types of noises from the windshield/rear glass area.

T-TT-0226-13

Service Bulletin/Repair Instructions

The customer is having difficulty changing the multi-display screen from Day Mode. If the multi-display screen is set to Day Mode when the headlights are on, the setting we be memorized when the engine is turned off.

T-SB-0391-08 Rev

Service Bulletin/Repair Instructions

This bulletin contains general vehicle pulling diagnosis and repair procedures along with specific information to help correct pulling complaints.

SST Requirements

Service Bulletin/Repair Instructions

SSTs are key elements to provide your customers with swift and accurate repairs resulting in superior customer satisfaction.

T-SB-0012-13

Service Bulletin/Repair Instructions

Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash calibration updates for specific vehicle models/ECUs are released as field-fix procedures described in individual Service Bulletins. This bulletin details the Techstream ECU flash reprogramming process and outlines use of the TIS and the CUW.

T-SB-0064-10 Rev

Service Bulletin/Repair Instructions

This bulletin is now obsolete. Please see T-SB-0012-13.

TSB-0087-12

Service Bulletin/Repair Instructions

TOYOTA: ACCELERATOR PEDAL SENSOR ASSEMBLY INFORMATION REGARDING THE INSPECTION, REMOVAL, AND INSTALLATION, IF LUBRICATION OR OIL, IS APPLIED. *PE

TSB-0122-11

Service Bulletin/Repair Instructions

TOYOTA: INFORMATION PROVIDED FOR REPLACING THE SEAT COVERS FOR VEHICLES EQUIPPED WITH SIDE AIRBAGS. *PE

TCS-11-022

Service Bulletin/Repair Instructions

TOYOTA SERVICE CAMPAIGN: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. UNUSUAL STEERING VIBRATION WHEN THE DRIVER RELEASES THE STEERING WHEEL. 2001-2003 PRIUS. *RM

POL-11-03

Service Bulletin/Repair Instructions

TOYOTA: UNUSUAL STEERING WHEEL VIBRATION WHEN THE DRIVER RELEASES THE STEERING WHEEL. WARRANTY EXTENSION. *RM

TSB-0064-10

Service Bulletin/Repair Instructions

TOYOTA: TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE. FLASH REPROGRAMMING ALLOWS THE ECU SOFTWARE TO BE UPDATED WITHOUT REPLACING THE ECU. FLASH CALIBRATION UPDATES FOR SPECIFIC VEHICLE MODELS/ECUS ARE RELEASED AS FIELD-FIX PROCEDURES DESCRIBED IN INDIVIDUAL SERVICE BULLETINS. MODEL YEARS FROM 2001-2011. *PE

SB-0180-09

Service Bulletin/Repair Instructions

TOYOTA: SOME VEHICLES MAY EXHIBIT A MIL ON CONDITION IF AN ABNORMALLY LOW ENGINE POWER OUTPUT OR FAILURE TO START HAS BEEN DETECTED DURING A PARTICULAR THS DRIVE CYCLE. *PE

02307

Service Bulletin/Repair Instructions

MALFUNCTION INDICATOR LAMP (MIL) ON DIAGNOSTIC TROUBLE CODE (DTC) P3130, AND INFORMATION CODE 346. *KB UPDATED 10/26/07. *NJ

01103

Service Bulletin/Repair Instructions

MASTER, HYBRID, AND MALFUNCTION INDICATOR LAMP (MIL) ON WITH DIAGNOSTIC TROUBLE CODES (DTC) P3190, P3191 AND P3101. *TT UPDATED 10/26/07. *NJ

00207

Service Bulletin/Repair Instructions

TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE. *KB

5074

Service Bulletin/Repair Instructions

DIAGNOSTICS - HV BATTERY CONTROL SYSTEM. REPAIR MANUAL CORRECTION. 00400-RM883-U1. 00400-RM778-U1. *TT

004008831

Service Bulletin/Repair Instructions

REPAIR MANUAL CORRECTION. *SC

05005

Service Bulletin/Repair Instructions

SPECIAL SERVICE CAMPAIGN (SSC) 40G - BATTERY MODIFICATION CHEMICAL UPDATE. *TT

4301

Service Bulletin/Repair Instructions

'02 PRIUS REPAIR MANUAL CORRECTION. 00400-RM883-U2. HYBRID VEHICLE CONTROL - HV BATTERY. *TT HV BATTERY CONTROL. 00400-RM883-U1. *TT

05004

Service Bulletin/Repair Instructions

ENGINE OIL SPECIFICATIONS. *TT

04014

Service Bulletin/Repair Instructions

SPECIAL SERVICE CAMPAIGN 40G. HV BATTERY MODIFICATION DATED 07/19/2004. *TT (REVISED). *TT

02204

Service Bulletin/Repair Instructions

MALFUNCTION INDICATOR LAMP (MIL) ON DIAGNOSTIC TROUBLE CODE P3130. *MJ

0403

Service Bulletin/Repair Instructions

WARRANTY ENHANCEMENT - ELECTRONICALLY ASSISTED POWER STEERING RACK ASSEMBLY. *TT

04010

Service Bulletin/Repair Instructions

CUSTOMER SUPPORT PROGRAM - WARRANTY COVERAGE ENHANCEMENT ON THE ELECTRONICALLY-ASSISTED POWER STEERING SYSTEM. *TT

00101

Service Bulletin/Repair Instructions

MAINTENANCE FOR HV AND AUXILIARY BATTERIES AT PORT AND DEALERS. REVISED. *TT

EL01403

Service Bulletin/Repair Instructions

CUSTOMER MAY COMPLAIN OF NOT BEING ABLE TO START THEIR VEHICLES AFTER EXTENDED PARKING TIMES AND/OR REPEATED SHORT DRIVING TIMES. THE PURPOSE OF THIS BULLETIN IS TO INFORM OF A NEW BATTERY AND MOUNTING HARDWARE TO IMPROVE THE STORAGE CAPACITY PERFORMANCE. *TT

00803

Service Bulletin/Repair Instructions

FUEL GAUGE INCLINATION METER RESET. *TT *JB

030503

Service Bulletin/Repair Instructions

MULTIPLEX COMMUNICATION SYSTEM - REPAIR MANUAL CORRECTION VOL I. *TT

02102

Service Bulletin/Repair Instructions

MASTER, HYBRID AND MALFUNCTION INDICATOR LIGHT ON CONDITION WITH DIAGNOSTIC TROUBLE CODE (DTC) P3125. *TT

EG01802

Service Bulletin/Repair Instructions

SOME VEHICLES MAY EXHIBIT A MASTER, HYBRID AND MALFUNCTION INDICATOR WARNING LIGHT ON WITH DIAGNOSTIC TROUBLE CODE P1120 SET. *TT

01202

Service Bulletin/Repair Instructions

MASTER, HYBRID AND MALFUNCTION INDICATOR LAMP WARNING LIGHT ON WITH DIAGNOSTIC TROUBLE CODE P3190, P3191 AND P3101. *TT

EL00602

Service Bulletin/Repair Instructions

THIS PURPOSE OF THIS BULLETIN IS TO CLARIFY THE NAVIGATION SYSTEM SPECIFICATIONS FOR CERTAIN VEHICLES. *TT

EG01502

Service Bulletin/Repair Instructions

SOME VEHICLES MAY EXPERIENCE A MALFUNCTION INDICATOR LIGHT ON WITH DIAGNOSTIC TROUBLE CODE P1436 STORED IN THE ENGINE CONTROL MODULE (ECM). *TT

EL01300

Service Bulletin/Repair Instructions

TECHNICAL INFORMATION REGARDING NAVIGATION, ENERGY MONITOR, CONSUMPTION AND CASSETTE EJECT MALFUNCTION. *TT

T-PG007-01

Service Bulletin/Repair Instructions

Replacement vin plates.

T-PG002-91

Service Bulletin/Repair Instructions

Product general information.

Reading this report

Complaint counts are reports filed with NHTSA, not failure rates. A common model collects more of them than a rare one that breaks more often.

2002 Toyota Prius Service Bulletins: 106 bulletins | CarFathom