Headlight problem

[johnhnhn]

Toyota replaced both my headlight bulbs today. The dealer said that there was a service bulletin out on it (T-SB-0030-08). They used #90981-20015 bulbs. It must be a very common problem as even the courtesy van drivers were aware of it.

Copy:
T-SB-0030-08 Rev1 April 11, 2008
HID Headlight System - Diagnostic Tips
Service
Category Vehicle Exterior
Section Lighting (ext) Market USA
Applicability
YEAR(S) MODEL(S) ADDITIONAL INFORMATION
2004 – 2008 Prius
TSB REVISION NOTICE
• May 12, 2008 Rev1: The part numbers referenced in the Note at the end of the Repair Procedure
have been corrected.
Any previous printed versions of this service bulletin should be discarded.
Introduction
The following bulletin is a supplement to the Repair Manual and provides diagnostics tips for
troubleshooting “Low Beam Does Not Turn On (One Side)”.
Parts Information
MODEL YEAR CURRENT PART NUMBER PART NAME QTY
2004 – 2005 90981-20007 1
2006 – 2008 90981-20015
Bulb, Discharge Headlamp
1
Warranty Information
OP CODE DESCRIPTION TIME OFP T1 T2
N/A Not Applicable to Warranty – – – –
© 2008 Toyota Motor Sales, USA Page 1 of 2
T-SB-0030-08 Rev1 April 11, 2008 Page 2 of 2
HID Headlight System - Diagnostic Tips
Required Tools & Equipment
SPECIAL SERVICE TOOLS (SST’S) PART NUMBER QTY
Digital Multimeter
(or Digital Volt Ohm Meter [DVOM] or Equivalent) 09082-00050 1
Terminal Gauge Set* 00002-48937-01 1
* Essential SST.
NOTE
Additional SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.
Repair Procedure
NOTE
If both low beam lights will NOT turn on, refer to the Repair Manual for diagnostics.
1. Using the SST or DVOM or equivalent, perform a voltage drop across connector H5/H3 pins 1
and 2.
SST P/N 09082-00050 or equivalent
• If reading is equal to source voltage, proceed to step 2.
• If reading is NOT equal to source voltage, isolate and repair the trouble area in the headlight
assembly power supply circuit.
2. Using the SST, check the pin fit of the 12V connector at the HID ECU.
SST P/N 00002-48937-01
• If pin fit is good, proceed to step 3.
• If pin fit is loose, repair or replace the connector and harness.
3. Switch the HID bulb between the left and right side.
• If the condition follows the HID bulb, replace the HID bulb.
• If the condition does NOT follow the bulb, replace the HID ECU.
NOTE
• The HID bulb and HID ECU service parts for 2004 – 2005 model year are NOT compatible
with 2006 and later model year vehicles. Installing a 2004 or 2005 model year HID
Bulb or HID ECU on a 2006 or later model year vehicle may cause an intermittent
operation/flickering of the HID bulb.
• In most cases, when replacing the HID bulb, the HID ECU does NOT need to be replaced.
In the event of HID ECU replacement, order the following part numbers: 81107-51050 (2004
– 2005 model year) or 81107-47150 (2006 – 2008 model year).
© 2008 Toyota Motor Sales, USA

[bruceha_2000]

Originally Posted by HokieHybrid

I can't believe they designed it that you have to remove the bumper to replace a bulb, especially if they are going to consider that bulb a replaceable part on a regular basis.

It has been said before, by me (possibly on this thread for all I know) and others:
There is NO reason to pull the bumper off to replace the headlight bulbs.

It isn't necessarily EASY due to the lack of room for your hands, but you can do it from inside the engine compartment in about 10 minutes after you do it slowly the first time to figure out what needs to be done. The most you have to disassemble is the air duct in front of the washer fluid reservoir and all that entails popping 2 of the plastic push fasteners. On the driver's side you can get a little extra room by removing the fuse box cover.

[warrior]

Originally Posted by AlphaTeam

They are HID's.
I'm not sure about the loose connection theory. But I'm not an expert on HID operation. But lets say that it was loose and I hit a bump light goes out. Why would be turning the lights off and back on make them go back on? If the circuit was open then switching them off and on would still not make it operate. If the connection opened and reclosed then why didn't it come back on by itself?

Gremlins?

[barbaram]

I can't believe they are not having a recall. I'm joining the club at 49,800 miles. The right side was replaced due to a hit and run. the left side is failing intermittently.
Thank you PRIUS CHAT for the info!!!
I filed with NHTSA and will be calling the dealer tomorrow about my repair!

[gcurtis42]

I was having this headlight problem. Fortunately I was still under the original warranty. (33,000 miles.) The dealership I purchased the car at just ordered me new HID's and everything seems to be fine.

[vettold]

I've been reading this topic for 18 months since I got pissed off at the toyota dealer. They wanted over 700 bucks for the two lights. So being pissed off for 18 months I drove around with one hand on the light switch while drive at night. I went to ebay as instructed on this site and purchased 2 lights from XEquipped@EBAY..

Stan Didenko
The price a whopping 88 bucks delivered to my door! I put them in and both worked. However after 3 hours the drivers side went out and I emailed stan and he said send the bad one back and I will send a new one. 10 days later the replacement came and has been working for 1 week. Toyota really dropped the ball on this one.


Thanks to this forum I saved over 600 bucks!!!

[suebeegrl]

I've been reading this topic for the past 7 months which is when I noticed the same problem with my 2006 Prius - driver's side headlight failing intermittently. I took my car to the Toyota dealer in May '08 and they said the sensor was defective and for $500 they could replace it. My car had 36k (past warranty), so I decided to wait. A month later I was in a car accident by an uninsured driver (side swiped) in the night time. The insurance company determined it was not my fault and paid over $5,000 for the repairs - which included replacing the leveler sensor attached to the rear axle. Unfortunately, this did not correct the headlight problem - which continues to fail; I was stopped by the police two days ago who issued me a warning about my headlight. I've reported this incident to the Toyota '800 number' and filed a complaint with the NHTSA. I'm hoping that the accident (which may have been caused by the defective headlight), will prompt a formal investigation and instigate a recall for the headlight controllers. I'll keep everyone posted if anything becomes of this.

[Ct. Ken V]

Hi, suebeegrl,

Your dealer is either clueless or a greedy BS'er. The sensor he claimed was defective has nothing to do with your HID headlights failing (turning off) intermittently. What a bad sensor usually does is tip the headlight aim way to low so you can only see about 20 feet ahead of you (but sometimes way too high) & either condition can happen without seeing any warning lights on the dash.

Ken (in Bolton,Ct)

[twhittak]

I have the same intermittent problem with the HID headlight on the drivers side. The dealer thinks replacing the bulb might help but......It does not appear to be connection related but a problem in the bulb or control circuits? I will contact Toyota and the national safety board.

Twhittak

[jimlyons]

Originally Posted by twhittak

I have the same intermittent problem with the HID headlight on the drivers side. The dealer thinks replacing the bulb might help but......It does not appear to be connection related but a problem in the bulb or control circuits? I will contact Toyota and the national safety board.

Twhittak

My dealer in Easton PA just replaced both bulbs - no charge! This is Dick Milham Toyota. Maybe give them a buzz and inquire as to their reasons for the free replacement - then tell your dealer.