Canada - Lighting - Premature Headlamp Low Beam Bulb Failure
T-TCI-3887October 19, 2012
HEADLAMP BULB DURABILITY ENHANCEMENT
Service Category
Vehicle Exterior
Section
Lighting (ext)
Market
Canada
APPLICABILITY:
INTRODUCTION:
Some 2010 - 2011 model year Prius vehicles may exhibit a condition where a halogen low beam headlamp bulb becomes inoperative earlier than expected. 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 that 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 ETAS / TIS library, applicable model and model year Repair Manual:
3. Remove the affected headlamp assembly.
Refer to the ETAS/TIS library applicable model and model year Repair Manual:
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 Terminal Removing Tool "F".
SST P/N: 09991-00510
(1) After the terminal cap is removed, gently insert 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 end.
F. Remove 10 mm of the wire outer coat insulation from engine wire No.4 (White-Black wire).
3G. Insert a section of heat shrink tubing (PIN 82999-30010) over engine wire No. 4.
H. Insert stripped bare wires into the sleeve tube (crimp connector) P/N 82999-52010 ensuring that 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 P/N 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 the headlamp temporarily connected to the wiring harness.
5. Reinstall the headlamp assembly.
Refer to the ETAS/TIS library applicable model and model year Repair Manual:
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 the connector from engine wire No.4 harness connector into the headlamp assembly.
B. Route the No. 4 harness starting at inner bumper reinforcement area following the contours of the factory harness. (Test fit routing as necessary to ensure fit.)
C. Apply nylon ties less than 100 mm from each other facing outward.
D. Trim ties after installation.
8. Right Side:
A. Plug the engine wire No. 4 harness connector into the headlamp assembly.
B. Test fit the routing of the 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 the ETAS/TIS library applicable model and model year Repair Manual:
10. Adjust headlamps.
Refer to the ETAS/TIS library applicable model and model year Repair Manual:
11. Verify normal operation of all affected systems.
NOTE:
Issue of the Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.
© 2012 Toyota Motor Sales, Canada