Canada - Body/Ignition - MIL ON/Misfire DTC's Set

Bulletin
TSB2403

Issue Date
2005-12-30

market
Canada

Title
M.I.L. "ON" DTC P0300, P0301, P0302, P0303, OR P0304

Component
ENGINE ELECTRICAL

Models
'04 - '05 Prius

INTRODUCTION:
Some 2004 and 2005 model year Prius vehicles may exhibit a M.I.L. "ON" condition with Diagnostic Trouble Codes P0300, P0301, P0302, P0303, or P0304. A possible cause for this condition is water collection within one or more of the spark plug tubes from a leak at the plastic cowl cover. Use the following procedure to diagnose and correct this condition.

APPLICABLE VEHICLES:
- 2004 - 2005 model year Prius vehicles.






PARTS INFORMATION:






REQUIRED TOOLS & MATERIAL:






WARRANTY INFORMATION:






REQUIRED SSTs:

REPAIR PROCEDURE:
1. Use the Toyota Diagnostic Tester to identify which cylinders have engine misfire DTCs.
2. Remove the affected ignition coil and cylinder spark plug. Refer to the ETAS 2004 or 2005 model year Prius Repair Manual: Ignition:
Ignition Coil No.1 (1NZ--FXE): Replacement.

3. Inspect the affected spark plug for surface corrosion and/or water. If present, replace the spark plug. Torque replacement spark plugs to the following specifications:

Torque: 18 N-m (184 kgf-cm, 13 ft-lbf)

NOTE:
If water intrusion is NOT the cause of the engine misfire, refer to the Repair Manual for diagnostic procedures.

4. Inspect the interior terminal on the affected ignition coil for corrosion. If present, replace the ignition coil.
5. Clear DTCs with the Diagnostic Tester and confirm engine operation.
6. Remove wiper arms and detach the driver's side plastic cowl cover. For further removal instructions, refer to ETAS, 2004 or 2005 model year Prius Repair Manual:






Wiper & Washer: Windshield Wiper Motor Assy: Replacement. Refer to the illustration for the location of the driver's side cowl cover.






7. The driver's side plastic cowl cover may be tilted to expose the area where both cowl covers are joined. Do NOT remove the weatherstrip that is bonded to the front of the plastic cowl covers. Remove the black foam seal where the driver's and passenger's side cowl covers join in the center.
8. Use Kent Acrysol(TM) (or equivalent) to remove the adhesive residue remaining from the black foam seal on the driver's and passenger's side cowl covers.
9. Reinstall the driver's side cowl cover to the vehicle.






10. Apply a small bead of seam sealer (Kent High Tech(TM) Clear Seam Sealer, or equivalent) to the seam between the driver's side and the passenger's side cowl covers at the location shown in the illustration.
11. Allow the seam sealer to dry for 15 minutes.
12. Confirm there are no gaps in the seam sealer to allow water to leak through.
Pour water over seam sealer to verify there is NO water leakage. If leakage is present, perform step 10 again to seal visible leak paths in seam sealer.
13. Reinstall the windshield wiper arms.

NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.