Lighting - Low Beam Headlamp Bulb, Short Life Span
T-SB-0204-12
October 17, 2012
Headlamp Durability Enhancement
Service Category
Vehicle Exterior
Section
Lighting (ext)
Market
USA
Applicability
Introduction
Some 2010 - 2011 model year Prius vehicles may exhibit a condition where a halogen low beam headlamp bulb lifetime is shorter than customer expectation. A modified wiring harness is available to address this condition.
Warranty Information
Parts Information
Required Tools & Equipment
Repair Procedure
1. Replace inoperative headlamp bulbs. After confirming headlamps work, verify headlight aim seems visually correct, and there is no sign of damage or alterations to wiring or headlamps.
NOTE
If a new bulb has been installed and the bulb is still inoperative, this bulletin does NOT apply. Please diagnose per the Repair Manual.
2. Remove the front bumper cover assembly.
Refer to the Technical Information System (TIS) applicable model and model year Repair Manual:
^ 2010 / 2011 Prius:
Vehicle Exterior - Exterior Panels/Trim - "Extenor Panels/Trim: Front Bumper: Removal"
NOTE
If the vehicle is equipped with headlight cleaners, be sure to drain the washer fluid system before bumper cover complete removal.
3. Remove the affected headlamp assembly.
Refer to TIS, applicable model and model year Repair Manual:
^ 2010 / 2011 Prius:
Vehicle Exterior - Lighting (Ext) - Lighting (Ext): Headlight Assembly: Removal"
4. Modify the existing Headlamp Harness and install the Engine Wire No.4 Harness.
A. Remove the green "cap" from the headlamp connector.
This can be accomplished by carefully using a small screwdriver or pick to detach the cap as shown in Figure 2.
B. After the cap is off remove terminal 2 (Violet wire) from the low beam headlight connector wire using the Terminal Removing Tool "F".
SST P/N: 09991-00510
(1) After the terminal cap is removed, gently insert the Terminal Removing Tool "F" into the connector between the terminal and the terminal lock (see Figures 1 and 3), then gently push the terminal lock to the outward side of the connector. Do not overstress the lock or it will not properly hold the terminal when reassembled.
(2) As the lock is held outward, gently tug on the Violet wire from the back of the connector to remove it.
C. Insert the terminal of Engine Wire No.4 (White-Black) in headlamp bulb No. 2 connector.
D. Cut the Violet wire previously removed from the headlamp bulb No.2 connector near the terminal.
E. Remove the wire outer coat insulation 10 mm from the edge.
F. Remove 10 mm of the wire outer coat insulation from Engine Wire No.4 (White-Black wire).
G. Insert a section of heat shrink tubing (PIN 82999-30010) over the Engine Wire No.4.
H. Insert stripped bare wires into sleeve tube (crimp connector) P/N 82999-52010, assuring the wires overlap in the center of the crimp.
I. Using the Wire Crimper SST, apply a 5.5 crimp to the center of the sleeve tube.
SST PIN 09042-2C100
J. Apply additional crimps slightly beyond the crimp in the center. The end result should look similar to that shown in Figure 8.
K. Slide the heat shrink tubing over the crimp and apply sufficient heat with a heat gun to close the heat shrink around the wire insulation.
L. Insert the headlamp connector back into the headlamp socket.
M. Test for normal high and low beam headlamp operation with headlamp temporarily connected to the wiring harness.
5. Reinstall the headlamp assembly.
Refer to TIS, applicable model and model year Repair Manual:
^ 2010 / 2011 Prius:
Vehicle Exterior - Lighting (Ext) - "Lighting (Ext): Headlight Assembly: Installation"
6. Install the Engine Wire No. 4 wire harness on the left or right side.
Be sure to attach nylon ties less than 100 mm apart.
7. Left Side:
A. Install connector from Engine Wire No.4 harness connector into the headlamp assembly.
B. Route No.4 harness starting at inner bumper reinforcement area following contours of factory harness. (Test fit routing as necessary to ensure fit.)
C. Apply nylon ties less than 100 mm from each other facing outward.
NOTE
Seven (7) tie wraps are needed for the left side. Ties number 6 and 7 are located closer together than other ties, exact distance depends upon routing.
D. Trim ties after installation.
8. Right Side:
A. Plug Engine Wire No.4 harness connector into the headlamp assembly.
B. Test fit routing No. 4 harness by following the contours, starting at the upper part of the factory wire harness area.
C. Apply nylon ties less than 100 mm from each other, facing outward.
D. Trim ties after installation.
9. Reinstall the bumper cover.
Refer to TIS, applicable model and model year Repair Manual:
^ 2010 / 2011 Prius:
Vehicle Exterior - Exterior Panels/Trim - "Exterior Panels/Trim: Front Bumper: Installation"
10. Adjust headlamps.
Refer to TIS, applicable model and model year Repair Manual:
^ 2010 / 2011 Prius:
Vehicle Exterior - Lighting (Ext) - "Lighting (Ext): Headlight Assembly: Adjustment"
11. Verify normal operation of all affected systems.
© 2012 Toyota Motor Sales, USA