TECHNICAL INSTRUCTIONS

FOR

SAFETY RECALL C0U

HYBRID ELECTRIC WATER PUMP REPLACEMENT

2004 – CERTAIN 2009 MODEL YEAR PRIUS

2

I. OPERATION FLOW CHART

Confirm C0T, Prius Steering Intermediate Extension Shaft Campaign is completed.

Verify Vehicle Eligibility1. Check the VIN range.

2. Check the TIS Vehicle Inquiry System.

No further action required.Not Covered

Campaign complete, return the vehicle to the customer.

Covered

Replace the HV water pump.

II. IDENTIFICATION OF AFFECTED VEHICLES

A. COVERED VIN RANGE

WMI Year VIN Range

VDS Range

JTD

2004 KB20U 0001175-0116869 KB22U 0001260-0116749

2005

KB20U 0116878-0133247 3000027-3128073 7004347-7057932

KB22U 0116886-0132689 3000115-3128039 7004602-7057877

2006 KB20U

3099688-3202420 7057977-7545072

KB22U 3128125-3202418 7056471-7544598

2007 KB20U 3202456-3296439 7083529-7694891

2008 KB20U 3291973-3462539 7690436-7818544

2009 KB20U 3458507-3546425 7815791-7894047

NOTE: • Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Safety Recall, and that the

campaign has not already been completed prior to dealer shipment or by another dealer. • TMS warranty will not reimburse dealers for repairs conducted on vehicles that are not affected or were

completed by another dealer.

3

III. PREPARATION

A. PARTS

Part Number Part Description Quantity 04000-32528 HV Electric Water Pump Kit* 1

*The kit above includes the following parts.

G9020-47031 HV Water Pump 1 90430-18008 Gasket 1

B. TOOLS & EQUIPMENT

• Radiator cap tester with adapter set C • Standard hand tools • Torque wrench • Transparent hose (inner diameter: approx. 6mm, length: approx. 450mm)

C. SUPPLIES

Part Name Quantity Toyota Genuine 50/50 Pre-Diluted SLLC Approximately 2.85 quarts

IV. BACKGROUND

There is a possibility that the coil wire of the electric motor installed in the Water Pump for the Hybrid System may have been scratched during the coiling manufacturing process at the supplier. In this condition, the coil wire may corrode at the scratched portion and in some cases break. If this occurs, the water pump could stop, leading to the illumination of various warning lights in the instrument panel. In limited instances, a short circuit can occur between adjacent coil wires, resulting in an open fuse for the electric power supply circuit. If the fuse is open, the hybrid system will stop while the vehicle is being driven, which may increase the risk of an accident.

V.

A

WORK PRA. COMPON

ROCEDURNENTS

RE

44

B

B. HV WATEER PUMP R

REMOVAL

1. R

a)

2. D

a)b)Nwin

c)d)

e)

f)

To

Nwin

3. R

a)

Nse

4. R

a)

b)

Nth

REMOVE THE) Remove

pocket to

RAIN THE C) Remove

) Remove

OTE: The inwhen removinjuries

) Remove

) Remove being reu

) Install a NReinstall

orque: 29ft. OTE: The in

when removinjuries

REMOVE THE) Remove OTE: Thereecure the br

REMOVE THE) Place an

on the 2 h

) DisconneOTE: The a

he hoses du

E KEY the key fro

o prevent othe

COOLANT Fthe 6 clips athe inverter rnverter / cooing the rese

the inverter dand cut the

used. NEW drain pthe drain plulbf (39N·m)

nverter / cooing the rese

E No.2 INVEthe 3 bolts a

e are 2 diffracket.

E HV WATE alignment mhoses.

ect the 2 hosealignment muring reasse

om the igniter from starti

ROM THE INnd the radiatreserve tank olant may berve tank c

drain plug. drain plug g

lug gasket. ug and torque

olant may berve tank c

ERTER BRACand the brackferent bolt t

R PUMP ASmark locating

es by loosenmark is used

mbly.

ion and keeingt the vehic

NVERTER tor support cocap.

be hot, take ap to preve

gasket to pr

e to specifica

be hot, take ap to preve

CKET ket. types (A &

SSEMBLY g the HV wa

ning the 2 clad to prevent

5

ep it in youcle.

over.

precautionsent potentia

revent it from

ation.

precautionsent potentia

B) used to

ater pump rib

amps. t twisting o

5

r

s l

m

s l

o

b

f

c)

d)

e)

f)g)

NO•

•

h)

i)

NO

) Remove

) Remove

) Plug the cloths.

Remove

) Place profrom ente

OTE: DO NOT awill cause Place the of the rela

) Remove out as sh

Place a mfrom bein

OTE: DO NO

the nut, bolt,

the connecto

HV water pu

the relay boxotective tapeering it when

allow coolan it to malfunprotective t

ay box.

the HV watehown. mark on the ng reused. OT allow coo

, and bracket

or and bolt.

ump ports w

x cover. e over the re

removing th

nt to enter tnction. tape so that

er pump from

original HV

olant to spill

t.

with paper tow

elay box to pe HV water p

the relay bo

t is covers a

m the vehicl

water pump

l onto the re

6

wels or shop

prevent watepump.

ox, doing so

all the edges

le by lifting i

to prevent i

elay box.

6

p

r

o

s

t

t

C

C. HV WATEER PUMP IN

NSTALLATIO

ON 1. IN

a)

b)c)

d)

e)

f)

g)

STALL THEInstall the vehicle as

Remove th

Reinstall th

Reinstall thTorque SpReconnect

Reinstall thspec. Torque Sp

Using the aclamps.

E NEW HV WNEW HV w

shown.

he protective he relay box c

he bolt and topec: 62in. lbft the connect

he bracket w

pec: 62in. lbf

alignment ma

WATER PUMPwater pump

tape from thcover.

orque to specf (7.0N·m) tor.

with the bolt

f (7.0N·m)

arks, reconne

P p by lowerin

e relay box.

c.

and nut, th

ect the 2 hos

7

g it into the

hen torque to

ses with the 2

7

e

o

2

2. RE

a)

3. AD

a)

b)

c)

NOlooatt

d)

e)

4. PE

a)b)

c)

d)

EINSTALL TReinstall thtorque to s

Torque: • Bolt A • Bolt B

DD COOLANPlace the r

Place a pableeder pluSupport antransparenapprox. 45reserve tan

OTE: Suppoosening it tachment br

Add coolareserve tan

Close the bTorque: 98

ERFORM A PTemporaril

Install the rPump the tfor coolant Remove th

THE NO. 2 INhe No. 2 inpec.

– 18ft. lbf (2– 16ft. lbf (2

NT reserve tank

aper towel oug. nd loosen thet hose (inne

50 mm) to ink. ort the bato prevent

racket.

nt until the nk FULL marbleeder plug 8in. lbf (11N

PRELIMINARy remove theradiator cap ttester to 29 kleaks.

he radiator ca

NVERTER BRnverter brack

25N·m) 21N·m)

hose in the u

or shop cloth

e bleeder pluer diameter:it and insert

ase of the t deformati

level in therking. and torque t

N·m)

RY COOLANe hose from ttester onto thkPa (0.3 kgf/

ap tester.

RACKET ket with the

upward posit

h underneath

ug screw, the: approx. 6 t the other

bleeder son or dam

e hose is ev

to spec.

NT LEAK TEthe reserve the reserve ta/cm2, 4.2 psi

8

3 bolts and

tion.

h the inverte

en connect amm, lengthend into the

screw whenmage to the

ven with the

EST tank. ank. ) and inspec

8

d

r

a :

e

n e

e

ct

c

d

c) Bleeding i. Looseii. Push

switchiii. Add civ. RepeNOTE: • The i

syste• Make

secobleed

d) Bleeding i. With

minutii. Wait

then siii. Repeiv. Add cNOTE: B• Steps• Air st• The i

The Inverteren the bleedethe power s

h the IG OFFcoolant to theeat steps “ii” a

nitial sound em. e sure to swinds the resding processThe Inverterthe bleeder

te, then switc1 minute, answitch the IG

eat steps “i” acoolant to the

Bleeding is cs “i” & “ii” htops comingnitial sound

r Cooling Syser screw. switch to turnF. e reserve tanand “iii” 3 tim

of the HV w

itch the IG Oserve tank s more difficr Cooling Sys

plug loosench the IG OFnd then switcG OFF. and “ii” a minie reserve tancomplete whhave been reg out of the d of the HV w

5. BL

a)b)

stem – Part 1

n IG ON and

nk until the lees, and verif

water pump w

OFF after 5 smay becomcult. stem – Part 2ned, switch tF. ch the IG ON

imum of 3 timnk until the lehen the followepeated a mbleeder scre

water pump

6. PE

a)

b)c)

d)

e)f)

g)

LEED THE INReinstall th

Verify thatmark.

1:

d operate the

vel is at the Ffy that the co

will subside

seconds. If tme empty, a

2: the IG ON a

N to operate

mes in order vel is at FULwing criteriainimum of 3ew. has subside

ERFORM A FClose the bTorque: 98

Remove th

Install the rPump the tfor coolant Remove th

Add coolanmark. Place the r

NVERTER Che hose to tht the reserve

e water pum

FULL mark. oolant level is

and become

the HV wateallowing air

and operate

the water p

to bleed the LL mark. a are met. 3 times.

ed and becoFINAL COOLbleeder plug 8in. lbf (11Nhe hose from radiator cap ttester to 29 kleaks.

he radiator cant to the rese

reserve tank

COOLING SYe reserve tane tank coola

mp for approx

s no longer d

e quieter as

er pump is or to enter t

the water p

ump for app

air from the

ome quieter.LANT LEAKand torque t

N·m) the reserve

tester onto thkPa (0.3 kgf/

ap tester. erve tank unt

hose back in

YSTEM nk. ant level if

ximately 5 s

ropping.

the air is ble

operated for the system

ump for app

proximately 1

cooling syste

. K TEST to spec.

tank and blehe reserve ta/cm2, 4.2 psi

til the level is

n the downwa

9

at the FULL

econds, then

eed from the

more than 5making the

proximately 1

minute, and

em.

eeder screw.ank. ) and inspec

s at the FULL

ard position.

9

L

n

e

5 e

1

d

ct

L

− C− C− C

VI.

A

Confirm the Confirm therConfirm C0T

If you ha

APPENDIA. CAMPAIG

As requirvehicle arreturn.

coolant is fre are no coT, Prius Stee

ave any ques

IX GN PARTS Ded by Federare disposed o

◄ VEilled and bleolant leaks

ering Interm

stions regar

DISPOSAL al Regulationof in a manne

h)i)

RIFY REed correctlyafter replacediate Exten

rding this up

ns, please maer in which th

Wipe any r

Reinstall th

EPAIR Qing the pumnsion Shaft

pdate, pleas

ake sure all chey will not b

residual coolahe radiator su

QUALITYmp

Campaign i

se contact yo

campaign pabe reused, un

ant. upport cover

Y ►

is completed

our regiona

arts (original nless reques

with the 6 cl

d

l representa

parts) removsted for par

10

ips.

ative.

ved from the rts recovery

0