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T-SB-0300-08
September 18, 2008
Abnormal Metallic Knock Noise from Front of Vehicle
| Service Category | Drivetrain | ||
|---|---|---|---|
| Section | Hybrid Transmission /Transaxle |
Market | USA |
Applicability
| YEAR(S) | MODEL(S) | ADDITIONAL INFORMATION |
|---|---|---|
| 2004 – 2008 | Prius | Plant Code(s): 3, 7 WMI(s): JTD |
Introduction
Some customers with 2004 – 2008 model year Prius vehicles may report a metallic knock or clunk noise from the engine bay heard only while driving over speed bumps or rough road conditions. The engine mount assembly has been improved to prevent this condition. Follow the repair procedure below to address customer concerns.
| NOTE
The affected mount is attached to the hybrid transaxle. The part name in this service bulletin is “Insulator, Engine Mounting, LH” (left-hand). The Repair Manual also refers to this part as “Engine Mounting Bracket No. 3”. |
Production Change Information
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown below.
| MODEL | PLANT | PRODUCTION CHANGE EFFECTIVE VIN* |
|---|---|---|
| Prius | Tsutsumi | JTDKB2#U#83430579 |
| Toyota Auto Body | JTDKB2#U#87793270 |
* Underlined number in VIN (11th digit) represents assembly plant line code.
Warranty Information
| OP CODE | DESCRIPTION | TIME | OFP | T1 | T2 |
|---|---|---|---|---|---|
| EG8040 | R & R Engine Mounting Insulator LH | 2.1 | 12306-21030 | 91 | 57 |
APPLICABLE WARRANTY
|
Parts Information
| PREVIOUS PART NUMBER | CURRENT PART NUMBER | PART NAME | QTY |
|---|---|---|---|
| N/A | 12372-21111 | Insulator, Engine Mounting, LH | 1 |
| 00272-SLLC2 | Same | Super Long Life Coolant (SLLC) | As Needed |
Required Tools & Equipment
| REQUIRED SST’S | PART NUMBER | QTY |
| Safety Gloves* | 00002-03100-S (Small) | 1 |
| 00002-03200-M (Medium) | ||
| 00002-03300-L (Large) |
* Essential SST.
| NOTE
Additional SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. |
Repair Procedure
After verifying that the “knock” noise is coming from the area near the hybrid transaxle, replace the engine mounting insulator LH with a NEW part.
- Remove the inverter w/converter assembly.
| NOTE
Do NOT replace the inverter. |
Refer to the Technical Information System (TIS), applicable model year Prius Repair Manual:
- 2004 / 2005 Prius: Engine/Hybrid System – Hybrid/Battery Control System – “W/converter Inverter Assy: Replacement”
- 2006 / 2007 / 2008 Prius: Engine/Hybrid System – Hybrid/Battery Control System – “P112 Hybrid Vehicle Control: Inverter With Converter: Removal”
- Support the hybrid transaxle assembly by using a transmission jack.
- Remove and replace the engine mounting insulator LH.
A. Remove the engine mounting insulator sub-assembly LH from the vehicle.
Figure 1.
| 1 | No. 3 Engine Mounting Bracket |
| 2 | Hybrid Vehicle Transaxle Assembly |
B. Remove two nuts from engine mounting insulator sub-assembly LH.
Figure 2. Engine Mounting Insulator Sub-Assembly (LH)
| 1 | Nut |
C. Replace the engine mounting insulator LH with the NEW part (P/N 12372-21111).
Figure 3.
| 1 | Old Part (Before Countermeasure) | 3 | EPT Sealer (10 x 35 mm [0.39 x 1.38 in.]) |
| 2 | NEW Part (After Countermeasure) | 4 | Added EPT Sealer (10 x 35 mm [0.39 x 1.38 in.]) |
D. Tighten the 2 nuts.
Torque: 64 N*m (640 kgf*cm, 47 ft*lbf)
E. Attach the engine mounting insulator sub-assembly LH on the vehicle.
Torque: 80 N*m (800 kgf*cm, 59 ft*lbf)
- Install the inverter w/converter assembly.
Refer to TIS, applicable model year Prius Repair Manual:
- 2004 / 2005 Prius: Engine/Hybrid System – Hybrid/Battery Control System – “W/converter Inverter Assy: Replacement”
- 2006 / 2007 / 2008 Prius: Engine/Hybrid System – Hybrid/Battery Control System – “P112 Hybrid Vehicle Control: Inverter With Converter: Installation”
- Road test to verify proper operation of the vehicle.
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