SAFETY RECALL 20TA10 – Hybrid System Software Update – 2013-2015 Toyota Prius & 2014-2017 Prius V

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June 24, 2020 NHTSA CAMPAIGN NUMBER: 20V369000

Hybrid System may Shutdown and cause Stall

An unexpected hybrid power system shut down may increase the risk of a crash.

 

NHTSA Campaign Number: 20V369

Manufacturer Toyota Motor Engineering & Manufacturing

Components HYBRID PROPULSION SYSTEM

Potential Number of Units Affected 266,638

 

Summary

Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2013-2015 Prius and 2014-2017 Prius V vehicles not included in recall 18V-684. Excessive voltage in the Intelligent Power Module (IPM) within the inverter may cause the hybrid system to shut down, causing the vehicle to stall while being driven.

 

Remedy

Toyota will notify owners, and dealers will perform a software update for the hybrid system. If the vehicle has experienced an inverter failure with certain hybrid system faults related to this condition, the inverter assembly will be repaired or replaced, prior to software update. All repairs will be performed free of charge. This recall began July 24, 2020. Owners may contact Toyota customer service at 1-888-270-9371. Toyota’s number for this recall is 20TB10 / 20TA10.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

Check if your Vehicle has a Recall

 


Certain 2013-2015 Model Year Prius
Certain 2014 – 2017 Model Year Prius V
Hybrid System Software Update NHTSA Recall No. 20V-369

 

Model / Years Production Period Approximate Total Vehicles Approximate Stop Sale Dealer Inventory
Prius / 2013 – 2015 Mid-March 2013 – Early November 2015 204,800 0
Prius V / 2014 -2017 Late June 2014 – Late November 2017 61,800 0

 

On June 24, 2020, Toyota filed a Defect Information Report (DIR) with the National Highway Traffic Safety Administration (NHTSA) informing the agency of our intent to conduct a voluntary Safety Recall on certain 2013 to 2015 model year Prius and certain 2014 to 2017 Prius V vehicles.

 

Condition

The involved vehicles were designed to enter a failsafe driving mode in response to certain hybrid system faults. Toyota has found that in rare situations, the vehicle may not enter a failsafe driving mode as intended. If this occurs, the vehicle could lose power and stall. While power steering and braking would remain operational, a vehicle stall while driving at higher speeds could increase the risk of a crash.

 

Remedy

Any authorized Toyota dealer will update the software for the hybrid system performed FREE OF CHARGE. For customer satisfaction, if the vehicle has experienced an inverter failure with certain hybrid system faults related to this condition, the inverter assembly will be repaired or replaced FREE OF CHARGE.

 

Covered Vehicles

There are approximately 266,600 vehicles covered by this Safety Recall. Approximately 120 vehicles were distributed to Puerto Rico.

 

Owner Letter Mailing Date

Toyota will notify owners by late August 2020.

Toyota makes significant effort to obtain current customer name and address information from each state through industry resources when mailing owner letters. In the event your dealership receives a notice for a vehicle that was sold prior to the Safety Recall announcement, it is the dealership’s responsibility to forward the owner letter to the customer who purchased the vehicle.

Please note that only owners of the covered vehicles will be notified. If you are contacted by an owner who has not yet received a notification, please verify eligibility by confirming through TIS prior to performing repairs. Dealers should perform the repair as outlined in the Technical Instructions found on TIS.

 

Dealer Inventory Procedures

New Vehicles in Dealership Inventory – Reminder

Toyota has not identified any new vehicles in dealership inventory that are covered by this Safety Recall. However, below is a reminder of the dealer’s obligations pertaining to Safety Recalls if there are new vehicles in dealership inventory:

Under Title 49, Section 30112 of the United States Code, a dealer cannot sell, offer for sale, or introduce or deliver for introduction in interstate commerce a new motor vehicle when it is aware that the vehicle does not comply with an applicable Federal Motor Vehicle Safety Standard or contains a defect related to motor vehicle safety.  Further, 49 Code of Federal Regulations §577.13 requires us to provide the following advisory:  It is a violation of Federal law for a dealer to deliver a new motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by this notification under a sale or lease until the defect or noncompliance is remedied.

Vehicle Safety Recall completion should always be verified through TIS. We request your assistance to ensure involved vehicles are identified and not delivered prior to performing the remedy.

NOTE: Dealers can identify if any of their new and used inventory has any open campaigns in the Vehicle Inventory Summary available in Dealer Daily (Non SET and GST dealers: https://dealerdaily.toyota.com/). The Vehicle Inventory Summary may take up to 4 hours to populate information for newly launched campaigns.

 

Pre-Owned Vehicles in Dealer Inventory

To ensure customer satisfaction, Toyota requests that dealers complete this Safety Recall on any used vehicles currently in dealer inventory that are covered by this Safety Recall prior to customer delivery. However, if the campaign cannot be completed (for example, due to remedy parts availability), delivery of a covered vehicle is acceptable if disclosed to the customer that the vehicle is involved in a Safety Recall.

Toyota expects dealers to use the attached Customer Contact and Vehicle Disclosure Form to obtain vehicle buyer information. Dealers are expected to provide a copy of the completed form, along with the most current FAQ, to the vehicle buyer. Toyota and the dealer may use this information to contact the customer when the remedy becomes available.

Keep the completed form on file at the dealership and send a copy to quality_compliance@toyota.com. In the subject line of the email state “Disclosure Form 20TA10/20TB10” and include the VIN.

NOTE: Dealers can identify if any of their new and used inventory has any open campaigns in the Vehicle Inventory Summary available in Dealer Daily (Non SET and GST dealers: https://dealerdaily.toyota.com/). The Vehicle Inventory Summary may take up to 4 hours to populate information for newly launched campaigns.

 

Toyota Certified Used Vehicle (TCUV)

The TCUV policy prohibits the certification of any vehicle with an outstanding Safety Recall, Special Service Campaign, or Limited Service Campaign. Thus, no affected units are to be designated, sold, or delivered as a TCUV until all applicable Safety Recalls, Special Service Campaigns, and Limited Service Campaigns have been completed on that vehicle.

 

Toyota Rent-A-Car (TRAC) & Service Loaners

Toyota requests that dealers remove all TRAC and Service Loaner vehicles from service that are covered by a Safety Recall unless the defect has been remedied.

 

Customer Handling, Parts Ordering, and Remedy Procedures

Customer Contacts

Customers who receive the owner letter may contact your dealership with questions regarding the letter and/or the Safety Recall. Please welcome them to your dealership and answer any questions that they may have. A Q&A is provided to assure a consistent message is communicated.

Customers with additional questions or concerns are asked to please contact the Toyota Customer Experience Center (1-888-270-9371) – Monday through Friday, 7:00 am to 7:00 pm, Saturday 7:00 am to 4:30 pm Central Time.

 

Salvage Title Vehicles

Every attempt should be made to complete an open Safety Recall when circumstances permit, unless noted otherwise in the Safety Recall dealer letter.

For complete details on this policy, refer to Toyota Warranty Policy 4.17, “What Is Not Covered by The Toyota New Vehicle Limited Warranty”.

 

Media Contacts

It is imperative that all media contacts (local and national) receive a consistent message. In this regard, all media contacts must be directed to Tania Saldana (859) 815-9968 in Toyota Corporate Communications. Please do not provide this number to customers. Please provide this contact only to media.

           

Parts Ordering Process Non SET and GST Parts Ordering Process

It is possible that parts for this campaign are either required to be ordered in Campaign Part Order Request (CPOR) on Service Lane, or have been placed on Manual Allocation Control (MAC) due to potential limited part availability. Please check the CPOR/MAC report on Dealer Daily for the most up-to-date parts ordering information.

All Safety Recall, Service Campaign (SSC/LSC) parts are eligible for the Monthly Parts Return Program. Please refer to PANT Bulletin 2011-087 for campaign parts that are currently returnable under the Monthly Parts Return Program and for additional details.

The required Authorized Modification Label to indicate the new software calibration ID can be ordered through the Material Distribution Center (MDC).

 

Part Number Description Quantity
00451-00001-LBL Authorized Modification Label 25 Per Pack

 

NOTE: Parts required for repair vary by model year and repair.  Refer to the Technical Instructions for diagnostic procedure.

 

Inverter component or assembly replacement MAY BE necessary based on the vehicle condition and diagnosis as per the technical instructions. ONLY ORDER the necessary parts based on the vehicle’s diagnosed condition. These parts can be found in the technical instructions.

The Power Management ECU is only needed if there is a reprogramming failure.

Model Part Number Description Quantity As Needed
Prius 89681-47253* Power Management ECU 1
Prius V 89681-47423* Power Management ECU 1
Prius V 89681-47031* Power Management ECU 1
Prius V 89981-47631* Power Management ECU 1
Prius V 89981-47231* Power Management ECU 1
Prius V 89681-47030** Power Management ECU 1
Prius V 89981-47630** Power Management ECU 1

 

*Does NOT require software update. 

 **Requires software update. 

 

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:

  • Expert Technician (Hybrid)
  • Master Technician
  • Master Diagnostic Technician

Always check which technicians can perform the repair 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. It 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.

 

Remedy Procedures

Refer to TIS for Technical Instructions on repair. Conduct all non-completed Safety Recalls and Service Campaigns on the vehicle during the time of appointment.

 

Repair Quality Confirmation

The repair quality of covered vehicles is extremely important to Toyota. To help ensure that all vehicles have the repair performed correctly, please designate at least one associate (someone other than the individual who performed the repair) to verify the repair quality of every vehicle prior to customer delivery.

 

Parts Recovery Procedures

All parts replaced as part of this Safety Recall must be turned over to the parts department until appropriate disposition is determined. The parts department must retain these parts until notification via the Parts Recovery System (PRS) is received indicating whether to ship or scrap the parts. These parts are utilized by various departments for defect analysis, quality control analysis, product evaluation, as well as other purposes.

To help minimize dealer storage challenges, Toyota recommends that dealers:

  • File the campaign claim accurately and promptly. The time a dealer is required to hold parts is based on when the campaign claim is paid by Toyota.
  • Monitor the Warranty Parts Recovery Notifications and Part Scrap Report regularly.

Refer to Warranty Policies 9.3 and 9.6 for additional details.

 

Vehicles Emission Recall Proof of Correction Form (California only)

As this Safety Recall includes emission related parts, California dealers are requested to fill out the Vehicle Emissions Recall – Proof of Correction form after repairs have been completed. The vehicle owner may require this form for vehicle registration renewal. It is important to note that the forms are an official state document and blank forms must be secured to prevent misuse. Booklets can be ordered from the MDC (material number 00410-92007).

Proof of Correction

Please complete the form and provide it to the owner. The first non-completed VINs will be submitted to the California state DMV by early March 2021. If the vehicle owner’s warranty claim will not be processed and paid prior to this date, please be sure to complete a form and provide it to a California owner.

 

Warranty Reimbursement Procedures

Loaner Vehicle or Alternative Transportation Reimbursement Procedure

There are no warnings that this condition exists. However, if the vehicle enters a fail-safe driving mode the following warning lights will be illuminated on the instrument panel when the vehicle enters the fail-safe driving mode.

 

Warning Lights (2014 – 2015 Prius V)
Hybrid System Warning Hybrid system warning
Slip Indicator Slip Indicator
Check Engine Warning Light Check Engine Warning Light
Electronically Controlled Brake System Warning Light

(Yellow Light)

Electronically Controlled Brake System Warning Light

 

 

Warning Lights
(2016 – 2017 Prius V and 2013 – 2015 Prius)

Master Warning Light Master Warning Light
Check Hybrid System Hybrid system warning message
Check PCS System PCS system warning message (if equipped)
NOTE: If PCS equipped.

Check Hybrid System

Display switches Check PCS System
Slip Indicator Slip Indicator
Check Engine Warning Light Check Engine Warning Light
Electronically Controlled Brake System Warning Light

(Yellow Light)

Electronically Controlled Brake System Warning Light

 

 

Until the remedy is performed, drivers should avoid placing a high load on the hybrid system by avoiding full throttle application when possible. As indicated in your Owner’s Manual, Toyota does not recommend towing with your vehicle, and we urge you to follow this recommendation to avoid placing a high load on the system.

If a customer is experiencing the condition described and is unable to drive it to the dealership, your dealership should arrange for vehicle pickup.

 

Warranty Reimbursement Procedure

Warranty Reimbursement Procedure

 

**NOTE**

  • Warranty Op Codes have 2 separate tables below. First table is for Prius only. Second table is for Prius V only.

 

Prius Vehicles ONLY

Description

1. Reprogram the Power Management ECU

 

2. Replace the Power Management ECU due to reprogramming failure (NO update to NEW ECU needed)

3. Replace the Power Management ECU due to reprogramming failure (UPDATE to NEW ECU needed)

4. Replace the IPM (Intelligent Power Module)

5. Replace the MG ECU

6. Replace the inverter current sensor sub-assembly

7. Replace the inverter assembly

 

Op Codes Description (Reference Chart Above) Flat Rate Time
1 2 3 4 5 6 7
A10001 0.7
A10002 1.3
A10003 1.9
A10004 3.6
A10005 3.6
A10006 3.7
A10007 2.7
A10008 4.2
A10009 4.2
A10010 4.3
A10011 3.3
A10012 4.8
A10013 4.8
A10014 4.9
A10015 3.9

 

  • The flat rate times include 0.1 hours for administrative cost per unit for the dealership.
  • A loaner vehicle or alternative transportation through the Toyota Rent-A-Car (TRAC) can be claimed, while the remedy is performed, for up to a maximum of 1 days as a sublet type “RT” under op codes: A10008, A1009, A1010, A1012, A1013, and A1014.
    • Rentals greater than 1 days or $35.00 per day requires DSPM authorization as per the Toyota Transportation Assistance Policy (TTAP).
    • Rental invoice MUST be attached to all rental claims. These claims may be subject to debit if rental invoice is not attached.
  • A loaner vehicle or alternative transportation through the Toyota Rent-A-Car (TRAC) can be claimed, due to back order of parts, for up to a maximum of 5 days as a sublet type “RT” under op codes: A10002, A10003, A10004, A10005, A10006, A10007, A10008, A10009, A10010, A10011, A10012, A10013, A10014, and A10015.
    • Rentals greater than 5 days or $35.00 per day requires DSPM authorization as per the Toyota Transportation Assistance Policy (TTAP).
    • Rental invoice MUST be attached to all rental claims. These claims may be subject to debit if rental invoice is not attached.
  • The cost of super long-life coolant will be reimbursed under sublet type “OF” for opcodes A10004, A10005, A10006, A10007, A10008, A10009, A10010, A10011, A10012, A10013, A10014, and A10015 up to 1.2 liters per vehicle for a MAX of $15.
  • Towing can be claimed under ALL remedy op codes for a maximum of $250 as sublet type “TW” in the event the customer requests vehicle pickup.
    • Towing invoice MUST be attached to all towing claims. These claims may be subject to debit if towing invoice is not attached.

 

Prius V Vehicles ONLY

Description

1. Reprogram the Power Management ECU

2. Replace the Power Management ECU due to reprogramming failure (NO update to NEW ECU needed)

3. Replace the Power Management ECU due to reprogramming failure (UPDATE to NEW ECU needed)

4. Replace the IPM (Intelligent Power Module)

5. Replace the MG ECU

6. Replace the inverter current sensor sub-assembly

7. Replace the inverter assembly

 

Op Codes Description (Reference Chart Above) Flat Rate Time
1 2 3 4 5 6 7
A10101 0.7
A10102 1.3
A10103 1.9
A10104 3.6
A10105 3.6
A10106 3.9
A10107 2.3
A10108 4.2
A10109 4.2
A10110 4.5
A10111 2.9
A10112 4.8
A10113 4.8
A10114 5.1
A10115 3.5

 

  • The flat rate times include 0.1 hours for administrative cost per unit for the dealership.
  • A loaner vehicle or alternative transportation through the Toyota Rent-A-Car (TRAC) can be claimed, while the remedy is performed, for up to a maximum of 1 days as a sublet type “RT” under op codes: A10106, A10108, A10109, A10110, A10112, A10113 and A10114.
    • Rentals greater than 1 days or $35.00 per day requires DSPM authorization as per the Toyota Transportation Assistance Policy (TTAP).
    • Rental invoice MUST be attached to all rental claims. These claims may be subject to debit if rental invoice is not attached.
  • A loaner vehicle or alternative transportation through the Toyota Rent-A-Car (TRAC) can be claimed, due to back order of parts, for up to a maximum of 5 days as a sublet type “RT” under op codes: A10102, A10103, A10104, A10105, A10106, A10107, A10108, A10109, A10110, A10111, A10112, A10113, A10114 and A10015.
    • Rentals greater than 5 days or $35.00 per day requires DSPM authorization as per the Toyota Transportation Assistance Policy (TTAP).
    • Rental invoice MUST be attached to all rental claims. These claims may be subject to debit if rental invoice is not attached.
  • The cost of super long-life coolant will be reimbursed under sublet type “OF” for opcodes A10104, A10105, A10106, A10107, A10108, A10109, A10110, A10111, A10112, A10113, A10114, and A10015 up to 1.2 liters per vehicle for a MAX of $15.
  • Towing can be claimed under ALL remedy op codes for a maximum of $250 as sublet type “TW” in the event the customer requests vehicle pickup.
    • Towing invoice MUST be attached to all towing claims. These claims may be subject to debit if towing invoice is not attached.

 

Claim Filing Accuracy and Correction Requests

It is the dealer’s responsibility to file claims correctly for this Safety Recall. This claim filing information is used by Toyota for various government reporting activities; therefore, claim filing accuracy is crucial. If it has been identified that a claim has been filed using an incorrect Op Code or a claim has been filed for an incorrect VIN, refer to Warranty Procedure Bulletin PRO17-03 to correct the claim.

 

Customer Reimbursement

Reimbursement consideration instructions will be included in the owner letter.

 

Campaign Designation / Phase Decoder

Campaign Designation / Phase Decoder
Examples:

19TA01 = Launched in 2019, Toyota, Safety Recall Remedy Phase, 1st Safety Recall Launched in 2019

20TC02 = Launched in 2020, Special Service Campaign, 2nd Special Service Campaign Launched in 2020

21TE05 = Launched in 2021, Customer Support Program, 5th Customer Support Program Launched in 2021

 

Please review this entire package with your Service and Parts staff to familiarize them with the proper step-by-step procedures required to implement this Safety Recall.

 

Thank you for your cooperation.

TOYOTA MOTOR SALES, U.S.A., INC.


SAFETY RECALL 20TA10 (Remedy Notice)

Certain 2013-2015 Model Year Prius
Certain 2014 – 2017 Model Year Prius V
Hybrid System Software Update
NHTSA Recall No. 20V-369

Frequently Asked Questions
Original Publication Date: June 24, 2020

 

Q1: What is the condition?

The involved vehicles were designed to enter a failsafe driving mode in response to certain hybrid system faults. Toyota has found that in rare situations, the vehicle may not enter a failsafe driving mode as intended. If this occurs, the vehicle could lose power and stall. While power steering and braking would remain operational, a vehicle stall while driving at higher speeds could increase the risk of a crash.

 

Q2: What is Toyota going to do?

When the remedy is available, Toyota will send an owner notification by first class mail advising owners to make an appointment with their authorized Toyota dealer to have the hybrid system software updated FREE OF CHARGE. For customer satisfaction, if the vehicle has experienced an inverter failure with certain hybrid system faults related to this condition, the inverter assembly will be repaired or replaced FREE OF CHARGE.

 

Q3: When will the remedy become available?

Toyota is currently developing the remedy. At this time, Toyota estimates that the remedy can be available in July 2020.

 

Q4: Are there any warnings that this condition exists?

No. There are no warnings that this condition exists. However, if the vehicle enters a fail-safe driving mode the following warning lights will be illuminated on the instrument panel when the vehicle enters the fail-safe driving mode.

 

Warning Lights (2014 – 2015 Prius V)
Hybrid System Warning Hybrid system warning
Slip Indicator Slip Indicator
Check Engine Warning Light Check Engine Warning Light
Electronically Controlled Brake System Warning Light

(Yellow Light)

Electronically Controlled Brake System Warning Light

 

 

Warning Lights
(2016 – 2017 Prius V and 2013 – 2015 Prius)

Master Warning Light Master Warning Light
Check Hybrid System Hybrid system warning message
Check PCS System PCS system warning message (if equipped)
NOTE: If PCS equipped.

Check Hybrid System

Display switches Check PCS System
Slip Indicator Slip Indicator
Check Engine Warning Light Check Engine Warning Light
Electronically Controlled Brake System Warning Light

(Yellow Light)

Electronically Controlled Brake System Warning Light

 

 

Q4a: How long and what distance can a vehicle be driven when the vehicle enters a fail-safe driving mode?

It differs in each model and with varying driving and environmental conditions. Generally, the failsafe mode is designed to allow the driver to operate the vehicle at reduced power for certain distances to allow the driver to maneuver the vehicle to a safe location.

 

Q4b: What should I do if my vehicle enters fail-safe driving mode?

If a vehicle enters a fail-safe driving mode, the driver should pull over and stop the car in a safe area at the earliest opportunity. The driver should then contact his/her local Toyota dealer for assistance.

Q4c: Can you describe what happens when the vehicle does not enter fail-safe driving mode as intended? Would the brakes still be operational?

The vehicle will run on inertia only. However, the brakes, power steering, and auxiliary systems such as turn signals will be operational as usual.

 

Q5: What steps can I take to reduce the possibility of this condition occurring until the remedy is performed?

Until the remedy is performed, drivers should avoid placing a high load on the hybrid system by avoiding full throttle application when possible. As indicated in your owner’s manual, Toyota does not recommend towing with your Prius or Prius V, and we urge you to follow this recommendation to avoid placing a high load on the hybrid system.

 

Q6: What if I experience the condition described above?

If you experience the condition described above, please contact your local authorized Toyota dealer for diagnosis and repair.

 

Q7: Which and how many vehicles are covered by this Safety Recall?

There are approximately 266,600 vehicles covered by this Safety Recall. Approximately 120 vehicles were distributed to Puerto Rico.

Model Name Model Year Production Period
Prius 2013 – 2015 Mid-March 2013 – Early November 2015
Prius V 2014 – 2017 Late June 2014 – Late November 2017

 

Q8: How long will the repair take?

The software update, when available, will take approximately 45 minutes to complete. If the inverter needs to be repaired or replaced, the repair could take up to 5.5 hours. However, depending upon the dealer’s work schedule, it may be necessary to make the vehicle available for a longer period of time.

 

Q9: What if I previously paid for repairs related to this Safety Recall?

Reimbursement consideration instructions will be provided in the owner letter.

 

Q10: How does Toyota obtain my mailing information?

Toyota uses an industry provider who works with each state’s Department of Motor Vehicles (DMV) to receive registration or title information, based upon the DMV records. Please make sure your registration or title information is correct.

 

Q11: What if I have additional questions or concerns?

If you have additional questions or concerns, please contact the Toyota Customer Experience Center at 1-888-270-9371 Monday through Friday, 7:00 am to 7:00 pm, Saturday 7:00 am to 4:30 pm Central Time.

 


Hybrid System Software Update – 2013-2015 Toyota Prius

 

SAFETY RECALL 20TA10 – Hybrid System Software Update – 2013-2015 Toyota Prius & 2014-2017 Prius V

 


Hybrid System Software Update – 2013-2015 Toyota Prius V

 

SAFETY RECALL 20TA10 – Hybrid System Software Update – 2013-2015 Toyota Prius & 2014-2017 Prius V

 


June 24, 2020

 

DEFECT INFORMATION REPORT

 

  1. Vehicle Manufacturer Name:

Toyota Motor Corporation [“TMC”]
1, Toyota-cho, Toyota-city, Aichi-pref., 471-8571, Japan

 

Affiliated U.S. Sales Company:

Toyota Motor North America, Inc. [“TMNA”]
6565 Headquarters Drive, Plano, TX 75024

 

Manufacturer of Hybrid Control ECU:
DENSO CORPORATION
1-1, Showa-cho, Kariya-city, Aichi, 448-8661, Japan
Telephone: + 81-566-25-5511

 

DENSO TEN Limited

2-28, Gosho-dori 1-chome, Hyogo-ku, Kobe-city, Hyogo, 652-8510, Japan
Phone: +81-78-671-5081

Country of Origin: Japan

 

  1. Identification of Involved Vehicles:
Make/Car Line Model Year Manufacturer Production Period
Toyota / Prius 2013-2015 TMC March 15, 2013 through November 9, 2015
Toyota / Prius v 2014-2017 June 20, 2014 through November 30, 2017

 

Applicability Part Number Part Name Component Description
MY2013-2015

Toyota Prius

89681-47440

89681-47441

89681-47250

89681-47251

Computer, Power Management Control Hybrid Control ECU
MY2014-2017

Toyota Prius v

89681-47030

89681-47422

89981-47630

Computer, Power Management Control

Computer, Hybrid Vehicle Control (2017MY)

 

NOTE: (1) Although the involved vehicles are within the above production period, not all vehicles in this range were sold in the U.S.

(2) Other Toyota or Lexus vehicles do not use the same hybrid control ECU and software as the involved vehicles or are involved in Safety Recall 18V-684.

 

  1. Total Number of Vehicles Potentially Involved:

Prius           : 204,835
Prius v        : 61,802
Total          : 266,637

 

  1. Percentage of Vehicles Estimated to Actually Contain the Defect:

Unknown.  Toyota is unable to provide an estimate of the percentage of vehicles to actually contain the defect.  Whether the issue in each case will lead to damage of the transistor within the inverter assembly and subsequently lead to a shutdown of the hybrid system, creating an unreasonable risk to safety, depends on each vehicle’s operating conditions.

 

  1. Description of Problem:

The subject vehicles were not involved in Safety Recall 18V-684 because they were originally equipped with a version of the software, used to control the boost converter in the Intelligent Power Module (IPM) within the inverter assembly of the vehicle’s hybrid system, that contains improved thermal management.   Repeated driving under certain identified high-load driving patterns (e.g., from a stop, applying nearly full throttle and then gradually further accelerating to full throttle) could cause higher thermal stress in specific transistors in the IPM, resulting in damage to those transistors over time.  This can lead to illumination of various warning lights and the display of a warning message on the instrument panel.  In cases where a specific transistor fails in a certain way during a high-load driving condition, such as during hard acceleration, there is a possibility for an abnormally high voltage to be generated that could exceed a certain limit in the software and IPM circuit design causing the hybrid system to shut down instead of entering a failsafe driving mode that would provide reduced motive power and allow the vehicle to be driven for certain distances.  In this condition, power steering and braking will not be affected.  However, a hybrid system that shuts down without entering a failsafe mode could result in the vehicle losing motive power while driving at higher speeds, increasing the risk of a crash.

 

  1. Chronology of Principal Events:

October 2018

On October 4, 2018, Toyota filed Safety Recall 18V-684, which did not include the subject vehicles.  Because the subject vehicles contained the improved thermal management logic when new, Toyota judged that it was unlikely that they would be affected by the condition in that recall.  However, Toyota continued monitoring the field information for the subject vehicles and collecting field parts for analysis.

 

August 2019 – January 2020

By this time, Toyota had recovered a number of inverter assemblies from the subject vehicles from the U.S market indicating potential hybrid inverter failure.  Toyota investigated the recovered inverter assemblies and found certain damaged transistors in the IPM.  However due to extent of the damage, the cause of the damage was not able to be identified.

 

As the field cases, up to this point, occurred predominantly in North America, Toyota hypothesized that there could be a previously unknown difference in the driving conditions in North America that could explain the different field experience in North America.

 

Thus, Toyota sought to compare the driving conditions between Japan and North America.  To do so, Toyota collected and analyzed driving data from a number of vehicles that were of another Toyota hybrid model, capable of communicating driving data wirelessly, that is sold in both regions.  (As the subject Prius and Prius v vehicles are not capable of communicating driving data wirelessly, a different hybrid model was used.)  Through this data, Toyota identified that there are potential differences between Japan and North America, in terms of vehicle speed and accelerator pedal application angle, under certain driving conditions, e.g., accelerator application patterns used to achieve rapid acceleration from very low speed.

 

Based on these findings, Toyota began testing to understand the potential effects of this type of driving pattern (where full throttle is applied from a stop) on the relevant transistors in the subject vehicles.  In parallel, in order to determine whether the driving patterns observed from the other hybrid model are similar to the driving patterns of Prius and Prius v drivers who have experienced these transistor failures, Toyota began collecting driving data from some customers who previously experienced this type of transistor failure by installing a recording device with the customer’s permission.

 

February 2020 – Early-June 2020

At this time, Toyota concluded the aforementioned testing to understand the potential effects on these transistors in the subject vehicles when they are exposed to a driving pattern where full throttle is applied from a stop.  In this testing, temperature in the transistors for the boost converter did not increase to a point which could cause damage to the transistors.

 

Based on this result, Toyota believed that there may be further differences in the driving pattern which could contribute to generating a higher temperature in these transistors.  Based on closer analysis of the driving data of the Prius customers who agreed to have a recording device installed, it was found that the unique driving pattern from these customers was not an application of full throttle from a stop.  Instead it was a pattern where, from a stop, the driver would apply the accelerator pedal rapidly up to approximately two third opening position and then gradually further accelerate to full throttle.

 

Further testing and analysis were conducted using this newly identified driving pattern and similar driving patterns.  This revealed that if the driver applies nearly full throttle from a stop and then gradually further accelerates to full throttle, the temperature generated in transistors for the boost converter could increase unexpectedly, beyond the levels created under prior testing where full throttle is applied directly from a stop.

 

Throughout this investigation, Toyota was also able to collect data from some vehicles that potentially experienced hybrid inverter failure that was retrieved when the vehicle was serviced by a dealer (i.e., freeze frame data contained within the hybrid control ECU).  At this time, Toyota was able to complete its detailed review and analysis of the available freeze frame data.  Through this analysis, Toyota identified eight data records that indicated that the hybrid system in a subject vehicle shut down instead of entering a failsafe driving mode due to an abnormally high voltage being generated.

 

Based on a result of the investigation above, it was found that, in spite of the improved thermal management logic in the software that was originally equipped in the subject vehicles, thermal damage could occur in certain transistors if the vehicle is exposed to repeated driving under certain identified high-load driving patterns over time.  In cases where a specific transistor fails in a certain way during a high-load driving condition, such as during hard acceleration, a large counter-electromotive voltage could be generated by the motor/generator at a capacitor within the IPM.  This large voltage, higher than the system limit, could be generated by the increase in RPM of the internal combustion engine and the motor generator attached to the engine.  If this were to occur, the hybrid system could shutdown, by design, in order to protect the system from electrical damage.  In this condition, power steering and braking will not be affected.  However, a hybrid system that shuts down without entering a failsafe mode could result in the vehicle losing motive power while driving at higher speeds, increasing the risk of a crash.

 

June 18, 2020

Toyota decided to conduct a voluntary safety recall campaign.

 

As of June 10, 2020, based on a diligent review of records, Toyota’s best engineering judgment is that there is one Toyota Field Technical Report and there are seven warranty claims that have been received from U.S. sources that relate to the condition investigated in this chronology and which were considered in the decision to submit this report.

 

  1. Description of Corrective Repair Action:

To address the safety defect, all known owners of the subject vehicles will be notified by first class mail to return their vehicles to a Toyota dealer to have a software update for the hybrid system performed at no cost.

For customer satisfaction, if the vehicle has experienced an inverter failure with certain hybrid system faults related to this condition, the inverter assembly will be repaired or replaced, prior to software update, at no cost.

 

Reimbursement Plan for pre-notification remedies

The owner letter will instruct vehicle owners who have paid to have this condition remedied prior to this campaign to seek reimbursement pursuant to Toyota’s General Reimbursement Plan.

 

  1. Recall Schedule:

Notifications to owners will be sent by August 23, 2020.  A copy of the draft owner notification will be submitted as soon as it is available.

 

  1. Distributor/Dealer Notification Schedule:

Notifications to distributors/dealers will be sent by June 24, 2020.  Copies of dealer communications will be submitted as they are issued.

 

  1. Manufacturer’s Campaign Number:

[Interim / Remedy] 20TB10 / 20TA10

 


7 Affected Products

Vehicles

MAKE MODEL YEAR
TOYOTA PRIUS 2013-2015
TOYOTA PRIUS V 2014-2017

 


16 Associated Documents

Manufacturer Notices(to Dealers,etc)

RCMN-20V369-9831.pdf 438.484KB

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Recall 573 Report-Amendment 1

RCLRPT-20V369-6392.PDF 217.14KB

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Recall 573 Report

RCLRPT-20V369-2746.PDF 217.14KB

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DEFECT INFORMATION REPORT

RMISC-20V369-2762.pdf 92.039KB

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Manufacturer Notices(to Dealers,etc)

RCMN-20V369-4210.pdf 203.772KB

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Remedy Instructions and TSB

RCRIT-20V369-0509.pdf 1804.651KB

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Manufacturer Notices(to Dealers,etc)

RCMN-20V369-2893.pdf 364.477KB

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Defect Notice 573 Report

RCLRPT-20V369-4351.PDF 217.139KB

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Recall Acknowledgement

RCAK-20V369-7552.pdf 291.341KB

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Remedy Instructions and TSB

RCRIT-20V369-0016.pdf 1883.91KB

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Recall 573 Report

RCLRPT-20V369-2518.PDF 217.139KB

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Recall Quarterly Report #1, 2020-3

RCLQRT-20V369-4806.PDF 211.169KB

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Manufacturer Notices(to Dealers,etc) – Toyota 7/28/2020 • The Warranty Reimbursement Procedure section has been updated. • The Parts Ordering Process section has been updated.

RCMN-20V369-2203.pdf 1204.532KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-20V369-6632.pdf 1497.975KB

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Recall Quarterly Report #2, 2020-4

RCLQRT-20V369-2833.PDF 211.283KB

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Recall Quarterly Report #3, 2021-1

RCLQRT-20V369-2948.PDF 211.381KB

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V369&docType=RCL

 


 

Reprogramming

J2534 Reprogramming

Approved J2534 Devices only provide reprogramming capabilities and do not support diagnostic scantool functions. For full diagnostic capabilities, please consider TIS Techstream or Techstream Lite

Toyota, Scion, and Lexus ECMs can be reprogrammed with the TIS Techstream, Techstream Lite, Diagnostic Tester, or can also be reprogrammed using a Toyota validated J2534 interface. Vehicle recalibration requires the use of the following:

  • Toyota validated J2534 interface
  • TIS Professional Level Subscription
  • Toyota Calibration Update Wizard software (installed along with Techstream Software)
  • Personal Computer running Microsoft Windows XP/2000 or later operating system

Toyota strongly recommends USING ONLY VALIDATED INTERFACE DEVICES that appear on this list.

Toyota works closely with J2534 interface manufacturers to ensure that their hardware works safely and efficiently with our products. Every device listed on this page has been thoroughly tested and validated on Toyota, Scion, and Lexus vehicles.

It is important to understand that only the specific devices, firmware, DLLs and APIs listed here have been tested by Toyota. We do not recommend use of any other J2534 device, firmware, DLL or API that is not listed here. Changes to J2534 hardware/software is outside of Toyota's control; in some cases, changes made to device hardware/software can negatively impact reprogramming performance. Toyota makes every effort to continue to work with J2534 interface manufacturers to ensure continued product compatibility as our respective products evolve.

 

J2534 Approved Device Application Chart

Device
Name
Supplier Version CUW
Version
Supported OS
Firmware* DLL* API*
Flasher LT-Import Bosch Diagnostics 01.02.07 01.02.07 04.04 8.8 B, C, D, E
Flasher PRO Bosch Diagnostics 01.09.18 01.09.18 04.04 8.8 B, C, D, E
Mastertech VCI Bosch Diagnostics 13.0.75.27 2.0.75.27 04.04 Testing in Progress B, C, D, E

VSI-2534

Dearborn Group 1.112 2.05.22 04.04 8.10 C, D

CarDAQ Plus

SAFETY RECALL 20TA10 - Hybrid System Software Update - 2013-2015 Toyota Prius & 2014-2017 Prius V | small light

Drew Technologies 01.09.18 01.09.18 04.04 8.8 B, C, D, E
Mongoose MFC Drew Technologies 01.02.07 01.02.07 04.04 8.8 B, C, D, E

Mongoose PRO

Drew Technologies 1.1.12.0 1.1.12.0 04.04 8.16 A, B, C, D
Pass Thru Pro II Snap-On 01.09.18 01.09.18 04.04 8.8 B, C, D, E

*Original validated firmware/DLL versions may be superceded by the device manufacturer. Contact the device manufacturer if you are unable to find the versions listed above.

 

Supported Operating Systems

A Windows 8 (32-bit; 64-bit)
B Windows 7 (32-bit; 64-bit)
C Windows VISTA Home Basic, Home Premium, Business, Ultimate
D Windows XP Pro SP1 or later
E Windows 2000 SP2 or later

For more information about the J2534 devices listed above, click on the vendor names. To report compatibility problems with listed hardware/software, please contact the device manufacturer.

 

SAFETY RECALL 20TA10 - Hybrid System Software Update - 2013-2015 Toyota Prius & 2014-2017 Prius V | small light CarDAQ-Plus 2 Diagnostic Code Reader and J2534 Programming Tool
SAFETY RECALL 20TA10 - Hybrid System Software Update - 2013-2015 Toyota Prius & 2014-2017 Prius V | small light Drew Technologies (DRWCDPLUSKIT) CarDAQ-Plus J2534 Flash Reprogramming Kit
SAFETY RECALL 20TA10 - Hybrid System Software Update - 2013-2015 Toyota Prius & 2014-2017 Prius V | small light CarDAQ-M Modular PassThru J2534 Vehicle Reflash Hardware
SAFETY RECALL 20TA10 - Hybrid System Software Update - 2013-2015 Toyota Prius & 2014-2017 Prius V | small light VSI J2534 ECU Reprogrammer & Diagnostic Adapter
Dearborn d-Bridge Adapter J2534 OBDII Engineering Tool
SAFETY RECALL 20TA10 - Hybrid System Software Update - 2013-2015 Toyota Prius & 2014-2017 Prius V | small light MAXIFLASH PRO (ALT-MF2534)

 


Obtaining Calibration Files

The Flash Reprogramming Calibration CD is no longer available.

ECU Calibrations are now available for download directly from TIS. A valid TIS Professional Level subscription is required to access Calibration files. These files are compatible with the above mentioned scantools and J2534 interfaces. The Calibration page, located on the Diagnostics tab in the TIS site, contains all the most current vehicle calibration files, applicable Service Bulletins, and instructions for use. Select the following link for step by step instructions to access this page.

Note: Calibration Update Software is now included in the Techstream Software Installer. A valid TIS Professional Level subscription is required to download and install Techstream Software.

 

https://techinfo.toyota.com

 


 

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Last update on 2024-04-17 / Affiliate links / Images from Amazon Product Advertising API

This product presentation was made with AAWP plugin.

 

 

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