Recall - Hybrid Vehicle ECU Reprogramming: Overview
TO: ALL TOYOTA DEALER PRINCIPALS, SERVICE MANAGERS, PARTS MANAGERSSUBJECT:
SPECIAL SERVICE CAMPAIGN (SSC) - 40D
(2004 MODEL YEAR PRIUS - ON-BOARD DIAGNOSTIC)
Toyota will initiate a Special Service Campaign (SSC) to reprogram the Electronic Control Units (ECUs) on certain 2004 Model Year Prius vehicles.
On certain 2004 Model Year Toyota Prius vehicles, the Hybrid Vehicle Electronic Control Unit (HV ECU) and Battery Electronic Control Unit (Battery ECU) may not conform to some portions of the diagnostic tool communication standard due to a programming error. If a repair facility's On-Board Diagnostic (OBD) scantool is used to diagnose a condition where the hybrid system warning light and/or master warning light is illuminated, the OBD scantool may not recognize the system fault.
The following vital information is provided to inform you and your staff of the campaign notification schedule and your degree of involvement.
1. Owner Notification Letter Mailing Date
The owner notification will commence in late May, 2004.
If you are contacted by an owner of an involved vehicle, who has not yet received a notification, please verify eligibility by confirming through Dealer Daily or TIS prior to performing repairs. Perform repairs as outlined in the Technical Instructions.
2. Identification of Involved Vehicles
Nationally, there are approximately 23,800 Model Year 2004 Prius vehicles involved in this special service campaign.
NOTE:
Not all vehicles in the VIN ranges are involved in this SSC. Always consult Dealer Daily or TIS to confirm VIN eligibility and to assure the SSC is applicable. This will verify the vehicle is involved and has not already been completed by another dealer or prior to dealer delivery. TMS warranty will not reimburse dealers of repairs conducted on vehicles that are not affected.
3. Vehicles in Dealer Stock
Dealerships are requested to perform the campaign procedure on any vehicles in their stock prior to sale or lease of the vehicles within the applicable period.
4. Dealer/Owner Lists
Dealer/Owner Lists for this campaign have been distributed to each dealership's Service and Parts Managers. These lists are based on selling dealership. Dealerships which did not sell an affected vehicle, or do not have affected vehicles in stock, will receive a report indicating so.
A UIO by state matrix is listed below to inform dealers of the number of vehicles in their area.
5. Repair Procedures
Refer to the Technical Instructions.
NOTE:
Prior to performing the repair, TMS Service Technology strongly recommends that all Diagnostic Tester Program Cards be updated to version 10.2a production (release 107) or a later version as soon as possible. Failure to upgrade to the most recent release could result in mis-diagnosis, ECU flash reprogramming errors or scantool performance issues.
6. Parts Ordering
Recalibration labels (packages of 25) are necessary for the completion of this campaign, which can be ordered through the Material Distribution Center (MDC). The Material Number is 00451-00001-LBL. No other parts are required, as the remedy involves only the electronic recalibration of the HV ECU software.
7. Reimbursement Procedures
Submit Special Service Campaign claims following the procedures described in the Toyota Warranty Policy and Procedures Manual.
The operation code to be used for this Special Service Campaign is shown.
NOTE:
The above flat rate time includes 0.1 hours of administrative cost per unit for the dealership.
NOTE:
Performance of SSC 40D cancels the need to complete any open SSC 40A repairs, which may be applicable to these vehicles. Dealers must submit any SSC 40A claims that were completed prior to the launch of 40D to TMS Warranty within 30 days. Warranty will debit all warranty claims for SSC 40A that are submitted with a repair date after the launch of SSC 40D.
8. Vehicles Registered in the State of California
The State of California requires the completion of Special Service Campaigns on emission-related parts prior to vehicle registration renewal. The state also mandates the submission of non-completed California VINs to the state Department of Motor Vehicles (D MV) by each auto manufacturer. Dealers in California will be requested to complete a Vehicle Emissions Recall Proof of Correction Form after the campaign has been completed to assure customers are able to provide proof of completion if requested by the DMV.
9. Vehicles Emission Recall Proof of Correction Form (California only)
As this Special Service Campaign 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. One book of the form has been included in the Service Managers package for dealers in California. It is important to note that the forms are an official state document and blank forms must be secured to prevent misuse. Additional books are available from the MDC (material part # 00410-92007).
Please complete the form as shown and provide it to owners of vehicles registered in California.
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 Special Service Campaign.
Thank you for your cooperation.
TOYOTA MOTOR SALES, U.S.A., INC.