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T-SB-0036-16May 12, 2016MIL "ON" DTC P0A94, P324E, P0A1A, and/or P3004ServiceCategoryEngine/Hybrid SystemSectionHybrid/Battery Control SystemMarket USAApplicabilityYEAR(S)MODEL(S)2012 - 2014Prius V2010 - 2014PriusADDITIONAL INFORMATIONIntroductionSome 2010 – 2014 Prius and 2012 – 2014 Prius V model vehicles may exhibit a MIL “ON”condition with DTCs P0A94, P324E, P0A1A, or P3004, indicating a malfunction has occurred inthe hybrid inverter assembly. To help identify the specific components within the inverterassembly that need to be replaced, follow the steps in this service bulletin to addressthe condition.Warranty InformationOP CODEDESCRIPTIONTIMEEL1602R & R the Inverter Assembly with Converter2.0EL1603R & R the IPM Transistor2.9EL1604R & R the IPM Transistor and theMG ECUOFPT1T2G9200-#####8A732.9APPLICABLE WARRANTYThis repair is covered under the Toyota Hybrid System Warranty. This warranty is in effect for 96months or 100,000 miles, whichever occurs first, from the vehicle’s in-service date.Warranty application is limited to occurrence of the specified condition described inthis bulletin. 2016 Toyota Motor Sales, USAPage 1 of 12
T-SB-0036-16May 12, 2016Page 2 of 12MIL "ON" DTC P0A94, P324E, P0A1A, and/or P3004Parts InformationNOTENot all parts listed are needed for HV inverter repair, this list is for reference only. Refer to thetables below for appropriate components based on the condition BEFORE ordering parts.PART NUMBER*PART NAMEG920H-47030G920H-47040Computer Sub-Assy, MG Controlw/BracketG920J-52010Sensor Sub-Assy, Inverter CurrentG9208-47090Wire Sub-Assy, Inverter04899-47021Transistor Kit, Power ModuleIntelligent (IPM)04899-47060Plug Kit, Inverter Drain90430-18008GasketG922L-47010Cover, Inverter Signal Connector91551-80618Bolt, FlangeQTY11(Required withany repairprocedure.)1(Parts notrequired,available in caseof breakage.)Seal, Masking, No. 11(Part included inIPM Kit,available in casespare isneeded.)08887-02809Toyota Thermal Grease X-23-7884-42(Used only forIPMreplacement.Product hasshelf life of 1year, do NOTuse if stored past1 year)08826-00100Seal Packing (or equivalent)00272-SLLC2Super Long Life Coolant091X1-47020* Part numbers are subject to change. 2016 Toyota Motor Sales, USA1
T-SB-0036-16May 12, 2016Page 3 of 12MIL "ON" DTC P0A94, P324E, P0A1A, and/or P3004Required Tools & EquipmentREQUIRED EQUIPMENTSUPPLIERTechstream 2.0*Techstream LitePART NUMBERQTYTS2UNITADETechstream Lite (Green Cable)TSLITEPDLR011TSLP2DLR01NOTEOnly ONE of the Techstream units listed above is required.Software version 11.10.034 or later is required.Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE)at 1-800-368-6787.SPECIAL SERVICE TOOLS (SST)PART NUMBERQTY00002-03100-S (Small)Electrical Insulating Gloves*00002-03200-M (Medium)100002-03300-L (Large)CAUTIONAlways inspect Electrical Insulating Gloves before use for cracks, ruptures, tears, pinholes, ordamage. Do NOT wear if damaged.NOTEAdditional SSTs may be ordered by calling 1-800-933-8335.SPECIAL SERVICE TOOLS (SST)PART NUMBERQTYOil Seal Puller*09308-000101Anti-Static Mat*09890-470101Squeegee*09891-470101Torque Wrench Adapter*09961-009501Inverter Case Separator*09891-470201* Essential SST. 2016 Toyota Motor Sales, USA
T-SB-0036-16May 12, 2016Page 4 of 12MIL "ON" DTC P0A94, P324E, P0A1A, and/or P3004Repair Procedure for 2010 – 2014 Prius VehiclesFigure 1.1. Confirm DTCs are present.2. If multiple DTCs are present, save the freeze frame data.3. After saving the freeze frame data, clear codes and confirm what DTCs reset.4. If multiple codes return, follow the repair manual diagnosis procedure for the DTC with FreezeFrame Data Occurrence Order value of “1”.5. Check the position of the Part Number labelon the inverter. Figure 2.Type A Inverters:Label is on side surface for allpart numbers.Label is on upper surface for partnumbers: G9200-47140,G9200-47141, G9200-47180 andG9200-47181 only. Type B Inverters:Label is on upper surface.6. Determine the repair components based oninverter type and DTC detail code.1Upper surface2Side surface 2016 Toyota Motor Sales, USA
T-SB-0036-16May 12, 2016Page 5 of 12MIL "ON" DTC P0A94, P324E, P0A1A, and/or P3004Repair Procedure for 2010 – 2014 Prius Vehicles (Continued)Use the correct table below to identify the parts required for repair. The correct parts are listed inthe bottom row of the table.Prius Inverter Type A: Required Parts by DTCDTCDTCDETAILCODEIPMREPLACEMENT MG-ECU CURRENT SENSOR INVERTER WIRE 7MG-ECUCURRENT SENSORINVERTERIPMASSEMBLYINVERTER WIRE HARNESSX127172 XX564X585X587X589X590X 2016 Toyota Motor Sales, USA
T-SB-0036-16May 12, 2016Page 6 of 12MIL "ON" DTC P0A94, P324E, P0A1A, and/or P3004Repair Procedure for 2010 – 2014 Prius Vehicles (Continued)Prius Inverter Type A: Required Parts by DTC (Continued) MG-ECU CURRENT SENSOR INVERTER WIRE HARNESS MG-ECUCURRENT SENSORIPMINVERTER IPM EMBLY131X132X800X801XPARTS & QUANTITY(QTY)FOR SPECIFIC DTCREPAIR04899-4702108887-0280904899-47060QTY 1QTY 2QTY 1G920J-52010G920H-47030G9208-47090QTY 1QTY 1QTY 1 2016 Toyota Motor Sales, USAG920H-47030 QTY 1G920J-52010 QTY 104899-47021 QTY 1G9200-49056QTY 100272-SLLC2QTY 1
T-SB-0036-16May 12, 2016Page 7 of 12MIL "ON" DTC P0A94, P324E, P0A1A, and/or P3004Repair Procedure for 2010 – 2014 Prius Vehicles (Continued)Prius Inverter Type B: Required Parts by DTCDTCDTCDETAILCODEIPM REPLACEMENTMG-ECU MG-ECU 56557P324E MG-ECU CURRENT SENSOR 8X659X791X792X793XP0A1A 2016 Toyota Motor Sales, USAINVERTERASSEMBLY
T-SB-0036-16May 12, 2016Page 8 of 12MIL "ON" DTC P0A94, P324E, P0A1A, and/or P3004Repair Procedure for 2010 – 2014 Prius Vehicles (Continued)Prius Inverter Type B: Required Parts by DTC (Continued)DTCDTCDETAIL IPM REPLACEMENTCODEP3004MG-ECU MG-ECU IPMMG-ECUCURRENT SENSORIPMINVERTERASSEMBLY131X132X800X801XPARTS 26-00100FOR SPECIFIC 90430-18008DTC REPAIR 00272-SLLC2QTY 1QTY 2QTY 1QTY 1QTY 1QTY -SLLC2QTY 1QTY 1QTY 1QTY 1QTY -0010090430-1800800272-SLLC2QTY 1QTY 2QTY 1QTY 1QTY 1QTY 1QTY 104899-47021 QTY 108887-02809 QTY 2G920H-47030 QTY 1G920J-52010 QTY 104899-47060 QTY 108826-00100 QTY 190430-18008 QTY 100272-SLLC2 QTY*G9200-49025(FORPRODUCTIONDATES OF04/2009-10/2013)QTY 1*00272-49075(FORPRODUCTIONDATES AFTER10/2013) QTY 100272-SLLC2 QTY1Repair Procedure for 2012 – 2014 Prius V VehiclesFigure 3.1. Confirm DTCs are present.2. If multiple DTCs are present save the freeze frame data. 2016 Toyota Motor Sales, USA
T-SB-0036-16May 12, 2016Page 9 of 12MIL "ON" DTC P0A94, P324E, P0A1A, and/or P3004Repair Procedure for 2012 – 2014 Prius V Vehicles (Continued)3. After saving the freeze frame data, clear codes and confirm what DTCs reset.4. If multiple codes return follow the RepairManual diagnosis procedure for the DTCwith Freeze Frame Data Occurrence Ordervalue of “1”.5. Check the position of the Part Number labelon the inverter.Figure 4.6. Type A Inverters:Label is on side surface for allpart numbers.Label is on upper surface for partnumbers: G9200-47160,G9200-47161, G9200-47162 ONLY.7. Type B Inverters:Label is on upper surface.1Upper surface2Side surface8. Determine repair components based on inverter type and DTC detail code.Use the correct table below to identify the parts required for repair, the correct parts are listed in thebottom row of the table.Prius V Inverter Type A: Required Parts by DTCDTCDTC DETAILCODEIPM REPLACEMENT MG-ECUCURRENT SENSORIPMINVERTER WIRE 5X587X589X590X 2016 Toyota Motor Sales, USAINVERTER ASSEMBLY
T-SB-0036-16May 12, 2016Page 10 of 12MIL "ON" DTC P0A94, P324E, P0A1A, and/or P3004Repair Procedure for 2012 – 2014 Prius V Vehicles (Continued)Prius V Inverter Type A: Required Parts by DTC PARTS & QUANTITY(QTY)FOR SPECIFIC 0090430-1800800272-SLLC2QTY 1QTY 2QTY 1QTY 1QTY 1QTY 1QTY 1QTY 1QTY 1QTY 2QTY 1QTY 1QTY 1QTY 1QTY 1G9200-49056 QTY 100272-SLLC2 QTY 1Prius V Inverter Type B: Required Parts by DTCDTCDTC DETAILCODEIPM REPLACEMENTXX442X548X550553P0A94XX555557 MG-ECU CURRENT SENSOR IPMX127172 MG-ECU IPMX564X585X587X589X590XP324E788XP0A1A151X 2016 Toyota Motor Sales, USAINVERTERASSEMBLY
T-SB-0036-16May 12, 2016Page 11 of 12MIL "ON" DTC P0A94, P324E, P0A1A, and/or P3004Repair Procedure for 2012 – 2014 Prius V Vehicles (Continued)Prius V Inverter Type B: Required Parts by DTC (Continued)131X132XP3004800X801XPARTS & QUANTITY(QTY)FOR SPECIFIC 10090430-1800800272-SLLC2QTY 1QTY 2QTY 1QTY 1QTY 1QTY -0010090430-1800800272-SLLC2QTY 1QTY 1QTY 2QTY 1QTY 1QTY 1QTY -4706008826-0010090430-1800800272-SLLC2QTY 1QTY 1QTY 1QTY 2QTY 1QTY 1QTY 1QTY 1G9200-49056 QTY 100272-SLLC2 QTY 1Repair Procedure 2010 – 2014 Prius and 2012 – 2014 Prius V Vehicles1. Repair the inverter. Refer to the Technical Information System (TIS), applicable model, andmodel year Repair Manual: 2010 Prius:Engine/Hybrid System – Hybrid/Battery Control – “Hybrid/Battery Control: Power ModuleIntelligent Transistor: Removal / Installation”2011 Prius:Engine/Hybrid System – Hybrid/Battery Control – “Hybrid/Battery Control: Power ModuleIntelligent Transistor: Removal / Installation”2012 Prius:Engine/Hybrid System – Hybrid/Battery Control – “Hybrid/Battery Control: Power ModuleIntelligent Transistor: Removal / Installation”2013 Prius:Engine/Hybrid System – Hybrid/Battery Control – “Hybrid/Battery Control: Power ModuleIntelligent Transistor: Removal / Installation”2014 Prius:Engine/Hybrid System – Hybrid/Battery Control – “Hybrid/Battery Control: Power ModuleIntelligent Transistor: Removal / Installation”2012 Prius V:Engine/Hybrid System – Hybrid/Battery Control – “Hybrid/Battery Control: Power ModuleIntelligent Transistor: Removal / Installation” 2016 Toyota Motor Sales, USA
T-SB-0036-16May 12, 2016Page 12 of 12MIL "ON" DTC P0A94, P324E, P0A1A, and/or P3004Repair Procedure for 2010 – 2014 Prius and 2012 – 2014 Prius V Vehicles (Continued) 2013 Prius V:Engine/Hybrid System – Hybrid/Battery Control – “Hybrid/Battery Control: Power ModuleIntelligent Transistor: Removal / Installation”2014 Prius V:Engine/Hybrid System – Hybrid/Battery Control – “Hybrid/Battery Control: Power ModuleIntelligent Transistor: Removal / Installation”2. Clear DTCs and confirm repair.HINTThe link below contains best practices when repairing the inverter.Quick Training Guide – QTG014B: Prius Inverter Repair Best Practices 2016 Toyota Motor Sales, USA
2012 - 2014 Prius V 2010 - 2014 Prius Introduction Some 2010 - 2014 Prius and 2012 - 2014 Prius V model vehicles may exhibit a MIL "ON" condition with DTCs P0A94, P324E, P0A1A, or P3004, indicating a malfunction has occurred in the hybrid inverter assembly. To help identify the specific components within the inverter
