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All Known Gen 4 Prius Recalls/Technical Service Bulletins (TSBs)

Discussion in 'Gen 4 Prius Care, Maintenance and Troubleshooting' started by Tideland Prius, Aug 24, 2017.

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  1. Tideland Prius

    Tideland Prius Moderator of the North
    Staff Member

    Oct 2, 2004
    Other Non-Hybrid
    This thread is locked. It is for reference and not for commenting out of fear that information would get lost in the discussion.

    You will find here a list of all known Toyota Service Bulletins and what they do and/or fix. Though we attempt to be as thorough as possible, this thread does not replace any information distributed by Toyota itself.

    If you are aware of any new TSBs, please PM a Staff Member.
    If you find an error or know of additional information about any of the TSBs listed here, please use the [Report] button and let us know.

    Please be aware that all Toyota service bulletins for North America are available by subscription to Toyota TIS, https://techinfo.toyota.com/, including bulletins not yet posted on NHTSA's site or other public sources.
  2. Tideland Prius

    Tideland Prius Moderator of the North
    Staff Member

    Oct 2, 2004
    Other Non-Hybrid

    Safety Recall G01 (16V741000)
    Parking Brake Cable May Disengage from Lever (2016–2017)
    Released: October 24, 2016
    Dealer Letter: https://static.nhtsa.gov/odi/rcl/2016/RCMN-16V741-4196.pdf
    Technical Instructions: https://static.nhtsa.gov/odi/rcl/2016/RCRIT-16V741-8569.pdf
    See: parking brake recall | PriusChat

    Safety Recall G0W (16V672000)
    Unintended Partial Passenger Air Bag Inflation (2016)
    Released: November 3, 2016
    Dealer Letter: https://static.nhtsa.gov/odi/rcl/2016/RCMN-16V672-3268.pdf
    Technical Instructions: https://static.nhtsa.gov/odi/rcl/2016/RCRIT-16V672-8211.pdf
    See: Recall on front passenger airbag Sept 14, 2016 | PriusChat

    Safety Recall 17R2 (Gulf States Toyota)
    Spare Tire Inflation Pressure (2017)
    Released: May 4, 2017
    Dealer Letter & Technical Instructions: https://static.nhtsa.gov/odi/rcl/2017/RCMN-17V295-2035.pdf
    See: Gulf States Toyota recall to set spare tire pressure (17V-295) | PriusChat

    Safety Recall H0U (17V658000)
    Improperly Bolted Hybrid Capacitor May Cause Stall (2016)
    Released: October 18, 2017
    Dealer Letter: https://static.nhtsa.gov/odi/rcl/2017/RCMN-17V658-6685.pdf
    Technical Instructions: https://static.nhtsa.gov/odi/rcl/2017/RCRIT-17V658-9449.pdf
    See: new recall Safety Recall H0U: 2016 Prius; Inverter Assembly Replacement | PriusChat

    Safety Recall J0F (J1F) (18V085000)
    Sensor Failures May Prevent Airbag Deployment (2016)
    Released: January 31, 2018
    Interim Dealer Letter: https://static.nhtsa.gov/odi/rcl/2018/RCMN-18V085-4439.pdf
    See: Air bag sensor recall for 2016 Prius | PriusChat
    Dealer Letter: https://static.nhtsa.gov/odi/rcl/2018/RCMN-18V085-2257.pdf
    Technical Instructions: https://static.nhtsa.gov/odi/rcl/2018/RCRIT-18V085-0302.pdf

    Safety Recall for Block Heater (Toyota Canada SRC R47/R48; also for Alaska)
    Released: July 20, 2017
    Transport Canada:
    Recall Details

    Press Release: Toyota Recalls Certain Accessory Block Heaters | Toyota Canada
    Alaska Notice: Kendall Auto Alaska | New Audi, Mazda, Volkswagen, Lexus, Kia, Porsche, Ford, Toyota, Subaru, Honda dealership in Fairbanks, AK 99701
    See: Prius Caught on Fire | Page 4 | PriusChat

    Safety Recall J0T (18V579000)
    Engine Wire Harness
    2016–2018 Prius
    Released: September 7, 2018
    Dealer Letter: https://static.nhtsa.gov/odi/rcl/2018/RCMN-18V579-3581.pdf
    Technical Instructions: https://static.nhtsa.gov/odi/rcl/2018/RCRIT-18V579-5292.pdf
    See: Engine wiring harness safety recall (model year 2016–2018)
    See: Wiring Harness Recall (J0T) - REMEDY UPDATE - Questions Remain

    Safety (Noncompliance) Recall K0L (19V544000)
    Potential Loss of Power Brake Assist (Brake Booster Pump)
    2019 Prius, 2019–2020 Prius Prime
    Released: September 19, 2019
    Dealer Letter: https://static.nhtsa.gov/odi/rcl/2019/RCMN-19V544-2564.pdf
    Technical Instructions: https://static.nhtsa.gov/odi/rcl/2019/RCRIT-19V544-5341.pdf
    See: Toyota recalls 2019 Prius, RAV4 Hybrid for faulty brake assist

    Noncompliance Recall 19R1 (19V244000) (Gulf States Toyota)
    Load Carrying Capacity Modification Label
    2019 Prius, 2019 Prius Prime
    Released: April 3, 2019
    Dealer Letter: https://static.nhtsa.gov/odi/rcl/2019/RCMN-19V244-3667.pdf

    Safety (Noncompliance) Recall 19TA21 (19V876000)
    Combination Meter Main Display May Become Inoperative
    2019 Prius
    Released: January 23, 2020
    Dealer Letter: https://static.nhtsa.gov/odi/rcl/2019/RCMN-19V876-3841.pdf
    Technical Instructions: https://static.nhtsa.gov/odi/rcl/2019/RCRIT-19V876-5972.pdf
    See: Recall for 2019 main display short circuit


    Limited Service Campaign G0T
    Certain 2016 Model Year Prius
    Simple Advanced Parking Guidance System (S-APGS)
    Released: July 21, 2016

    Toyota’s Limited Service Campaign K0P

    “Safety Connect System – Vehicle Location Inaccurate”
    Certain Prius (2013–2017), Prius V (2012–2017), 4Runner (2013–2019), Land Cruiser (2011–2017), and Mirai (2016–2017) vehicles that have the optional Safety Connect system. There is a similar campaign (KLG) for certain Lexus vehicles.
    Released: Sept 18, 2019

    (Also known as Customer Support Program 19TE12)
    Dealer Letter: https://static.nhtsa.gov/odi/tsbs/2019/MC-10168527-9999.pdf
    Technical Instructions: https://static.nhtsa.gov/odi/tsbs/2019/MC-10168528-9999.pdf

    The problem is in the Data Communication Module (DCM), the cellular modem and GPS receiver used by Safety Connect. Toyota writes, “Due to incorrect programming in the DCM software, after November 2nd, 2019, the GPS coordinates for this system will be calculated incorrectly. This will cause the system to use incorrect vehicle coordinates if one of the system’s features is activated.”
    Safety Connect locations wrong after Nov. 2, 2019 (Toyota Campaign K0P) | PriusChat

    Special Service Campaign J0R
    Intelligent Clearance Sonar (ICS) System Reprogram
    2016–2018 Prius, 2017–2018 Prius Prime
    Released: October 31, 2018
    Dealer Letter: https://static.nhtsa.gov/odi/tsbs/2019/mc-10159722-9999.pdf
    Technical Instructions: https://static.nhtsa.gov/odi/tsbs/2019/MC-10159705-9999.pdf
    See: J0R - Prius Special Service Campaign
    See: Recall for ICS reprogramming

    Technical Service Bulletins

    Battery Maintenance During PDS (2016*)
    Released: December 14, 2015

    T-SB-0127-15 (Rev1)
    2016 Prius Pre-Delivery Service Check Sheet
    Released: January 19, 2016

    T-SB-0128-15 Rev1
    2016 Prius Pre-Delivery Service (PDS)
    Released: January 19, 2016

    2017 Prius Pre-Delivery Service Check Sheet
    Released: August 30, 2016

    2017 Prius Pre-Delivery Service (PDS)
    Released: August 30, 2016

    Smart Key System Check During PDS (2017*)
    Released: May 12, 2016

    Floor Mat Installation During PDS (2017*)
    Released: May 12, 2016

    T-SB-0039-16 (Rev1)
    Battery Maintenance During PDS (2017*)
    Released: May 13, 2016

    Tire Positioning Before New Vehicle Delivery (2017*)
    Released: May 16, 2016

    Maintenance for HV & Auxiliary Batteries (2017*)
    Released: May 18, 2016

    Paint Stains Under Rapgard (2010–2016*)
    Released: May 19, 2016

    Long-Term Vehicle Storage Guidelines (2017)
    Released: May 19, 2016

    Techstream ECU Flash Reprogramming Procedure (2001–2017*)
    Released: September 14, 2016

    T-SB-0142-13 (Rev2)
    HVAC Odor Maintenance (2004–2017*)
    Released: November 10, 2016

    Interior Electrical Component Precautions (1988–2017*)
    Released: January 6, 2017

    T-SB-0144-16 (Rev1)
    Click Noise From Rear While Driving (2016)
    Released: October 5, 2016
    Revised: January 26, 2017


    Applicable to cars with VINs earlier than JTDKBRFU#G3006967 or JTDKARFU#G3007491, and only if they “exhibit a clicking noise from the support nuts on the rear shocks.

    See: Strange clunk noise from rear | PriusChat

    Toyota Safety Sense Front Camera Optical Axis Learning Information (2016-2017*)
    Released: February 1, 2017

    Buzzing Noise From LH Side Under Dash
    Released: March 2, 2017

    Applicable to 2016 model year Prius cars with VINs earlier than JTDKARFU#G3523018 (Tsutsumi Line 2) or JTDKBRFU#G3017940 (Tsutsumi Line 1), but only if they have the buzzing noise. Toyota explains the cause: “The pin that secures the center section of the HVAC duct together may be loose."

    TSB Issued for Buzzing rattle in dashboard | PriusChat

    T-SB-0044-16 (Rev1)
    Paint Stains Under Rapgard (2010–2017*)
    Released: March 7, 2017

    T-SB-0033-14 (Rev1)
    HVAC Evaporator Drain Hose Clogged Due to Insect Intrusion (2006-2017*)
    Released: March 8, 2017

    T-SB-0103-16 (Rev2)
    Entune Audio Head Unit Software Update (Panasonic) (2016-2017*)
    Released: April 4, 2017
    See: Head Unit Replacement | PriusChat

    T-SB-0103-16 (Rev2) — Superseded by T-SB-0279-17
    Entune Audio Head Unit Software Update (Panasonic) (2016-2017*)
    Released: September 8, 2017
    See: What company actually makes the radio units in the Prius lineup? | PriusChat

    SRS Component Disposal as Hazardous Material Treatment (1988–2018*)
    Released: May 19, 2017

    Difficult to Refuel Vehicle Due to Fuel Filler Door Switch Interference
    Released: May 23, 2017


    The bulletin is applicable to 2016 and 2017 model year Prius cars with VINs earlier than JTDKBRFU#H3038680 (Tsutsumi Line 1) or JTDKBRFU#H3552934 (Tsutsumi Line 2), and also to 2017 model year Prius Prime cars with VINs earlier than JTDKARFP#H3012455, but only if the fuel filler door does not open completely when the fuel door open button is pressed, which can cause the fuel vapor containment valve to close prematurely. The bulletin links to videos showing examples of complete and incomplete door opening.

    Fuel Filling Problem | PriusChat

    Reduced Power When Accelerating From a Stop (2016–2017)
    Released: July 27, 2017
    See: TSB (NiMH only): Reduced power when accelerating from a stop | PriusChat

    On November 27, 2017, Toyota issued Service Bulletin T-SB-0319-17, “MIL "ON" DTC P05A072 Due to Debris Stuck in the Active Grille Shutter,” applicable to 2016 and 2017 Prius and 2017 Prius Prime cars sold in the U.S., but only if:
    • There is a “Grille Shutter Inoperative” message, diagnostic trouble code P05A072, or both;
    • Inspection of the grille shutter finds “debris or witness marks where debris may have caused the grille shutter to stick open”; and
    • The vehicle was made before the relevant production change, i.e., it has a VIN earlier than JTDKBRFU#H3050432 (Prius, Tsutsumi Line 1), JTDKBRFU#H3570595 (Prius, Tsutsumi Line 2), or JTDKARFP#H3039725 (Prius Prime).
    The countermeasure is to replace the radiator shutter sub-assembly, lower front bumper absorber, and swing grille actuator assembly with new parts, presumably of improved design. The bulletin includes work instructions but also refers to the Repair Manual for parts of the procedure. The repair is covered by the Federal, California, or state-specific emissions warranty, subject to its terms.

    See: TSB: Debris stuck in active grille shutter (DTC P05A072) | PriusChat

    “Multimedia System Enhancements (Panasonic),” published December 21, 2017, Toyota writes, “Some customers may complain of the inability to use certain functions of the navigation/infotainment system while the vehicle is in motion. The following software update modifies the system functionality while the vehicle is in motion, improving customer experience.”

    The bulletin officially applies only to Panasonic head units in model year 2018 vehicles, but from the part numbers, software versions, and file names, it may be that the updated software might also work with the 2016–2017 head units. I haven’t investigated this, and you proceed at your own risk. For Entune Audio, the latest version is 01014B (13TBDANA-DA10_0075.kwi), and for Entune Premium Audio, the latest version is 010192 (13TDANNA-DA11_0146.kwi).

    Note that these bulletins do not apply to the 11.6-inch head units made by Denso used in certain grades of the Prius Prime or 2018 Prius. See T-SB-0236-17 Rev1 for details.

    MIL "ON" DTC P1CB7A2 (2016)
    Released: February 16, 2018

    Software update for hybrid vehicle control ECU on 2016 Prius cars, before JTDKBRFU_G3012347 (NiMH) or JTDKARFU_G3014652 (Li-Ion), only if trouble code P1CB7A2 (Motor Generator System Voltage Low) is present. Inverter battery may also be replaced. Covered under hybrid warranty (96 months/100,000 miles).

    T-TCI-5089 (Canadian TSB)
    “Condensation Dripping from the Headliner,”
    April 13, 2018, for the 2016–2018 Prius and 2017–2018 Prius Prime.

    In areas with quick temperature fluctuations, some customers may observe signs of water entry in the sides of the headlining & map lamp area due to condensation.” The countermeasure, applicable only to vehicles with the problem, is to “insulate the areas between the roof cross bows, front & center pillar and near the map lamp” using pads, part numbers 63341-12340, 63342-12270, 63314-12180, and 63351-12070, according to a detailed repair procedure in the bulletin.
    TSB (Canada): Condensation Dripping from the Headliner | PriusChat

    On December 13, Toyota issued Service Bulletin T-SB-0157-18, “Click Noise From LF Wheel Area During Deceleration,” applicable to 2016–2019 model year Prius cars sold in the U.S. that “exhibit a click noise from the LF wheel area upon deceleration and/or braking.”

    The countermeasure is to replace the LH Front Drive Shaft Assembly, original part number 43420-47040, with a new one, part number 43420-47050. Dealers are allowed 1.7 hours of labor to make the replacement, which is done according to procedures already published in the Repair Manual (more info) under Drivetrain: Drive Shaft/Propeller Shaft: Front Drive Shaft Assembly. In the U.S., the repair is covered by the Toyota Powertrain Warranty (60 months or 60,000 miles), but only if the symptom described in the bulletin is present.

    Clicking Sound on Regen Braking | Page 9 | PriusChat

    T-SB-0157-18 has been withdrawn. See Clicking Sound on Regen Braking | Page 12 | PriusChat

    Leather and Synthetic Leather Care Best Practices
    Released: February 2, 2018

    How to clean leather and SofTex fabric.

    MIL ON DTC P261093 (2016–2018)
    Released: January 16, 2019

    Software update for Engine Control Module (ECM).

    Low Coolant, MIL ON DTC P148F00, and/or Poor Heater Performance (2016–2019)
    Released: September 26, 2019

    Entune Audio Head Unit Software Update (Panasonic)
    Released: January 13, 2020

    Oil Leak Diagnosis and Repair
    Released: January 27, 2020

    How to distinguish a fluid leak, needing repair, from a fluid seep.

    Audio Head Unit Software Update (Denso) (2019–2020)
    Released: April 1, 2020

    Audio Head Unit Software Update (Denso-Ten) (2020)
    Released: May 11, 2020

    HV Battery Cooling System Maintenance
    Released: June 18, 2020

    Cleaning the intake filter for the battery cooling fan.

    Vehicle Pull, Steering Wheel Off Center, and Alignment Best Practices
    Released: June 23, 2020
    (Not available from NHTSA at this writing.)

    23 pages of general information on resolving alignment complaints.

    MIL ON With DTC P0A80/P1AC000 and/or P0A7F/P1A8000 Due to Dust or Debris in the HV Battery Cooling Fan/Filter (2003–2020)
    Released: August 5, 2020
    (Not available from NHTSA at this writing.)

    Special thanks to @Elektroingenieur for the contribution!
    #2 Tideland Prius, Aug 24, 2017
    Last edited: Nov 20, 2020
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