Canada - Engine - Abnormal Metallic Knock Noise Front Of Veh.

Bulletin
TSB3056

Issue Date
September 19, 2008

Market
Canada

Title
Abnormal Metallic Knock Noise from Front of Vehicle

Component
Engine Mechanical

Models
'04 - '08 Prius

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".






APPLICABLE VEHICLES:

PRODUCTION CHANGE INFORMATION:







This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.






WARRANTY INFORMATION:






PARTS INFORMATION:






REQUIRED SSTS:

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.

1. Remove the inverter w/converter assembly.

NOTE
Do NOT replace the inverter.

Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Prius
- Year: 2004-2005
- Service Category: Engine/Hybrid System
- Section: Hybrid/Battery Control system
- Keyword: W/converter Inverter Assy: Replacement


Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Prius
- Year: 2006-2008
- Service Category: Engine/Hybrid System
- Section: Hybrid/Battery Control system
- Keyword: P112 Hybrid Vehicle Control: Inverter With Converter: Removal

2. Support the hybrid transaxle assembly by using a transmission jack.
3. Remove and replace the engine mounting insulator LH.







A. Remove the engine mounting insulator sub-assembly LH from the vehicle.







B. Remove two nuts from engine mounting insulator sub-assembly LH.







C. Replace the engine mounting insulator LH with the NEW part (P/N 12372-21111).
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)

4. Install the inverter w/converter assembly.

Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Prius
- Year: 2004-2008
- Service Category: Engine/Hybrid System
- Section: Hybrid/Battery Control system
- Keyword: - W/converter Inverter Assy: Replacement (2004 - 2005)
- P112 Hybrid Vehicle Control: Inverter With Converter: Removal (2006-2008)

5. Road test to verify proper operation of the vehicle.

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.