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Canada - Engine Controls - Master/Hybrid MIL ON/DTC P3115





Bulletin
0972

Issue Date
2001-05-25

Reference
EE-01-06

Model
Prius

Year Range
2001

Market
Canada

Component
EE

Subject:
MASTER, HYBRID & M.I.L. LIGHTS "ON", P3115

Some 2001 model year Prius vehicles may exhibit a Master, Hybrid & M.I.L. Warning Lights "ON" condition. This condition can occur under the following circumstances:

1. While decelerating with a slight accelerator pedal opening and with many electrical accessories in use. Diagnostic Trouble Codes P3115 will set in the HV Battery ECU & P3000 in the HV ECU.
2. After turning the IG key to "Start" for the 1st trip after a cold soak in ambient temperatures below 32°F (0°C), Diagnostic Trouble Code P3115 will set in the HV ECU.

The HV ECU software was modified to correct this condition. Use the following procedure to replace the HV ECU.

APPLICABLE VEHICLES:
2001 model year Prius vehicles.





PRODUCTION CHANGE INFORMATION:





PARTS INFORMATION:

REPAIR PROCEDURE:

A. Please refer to Figure 1 and the following instructions to remove and replace the HV ECU:

1. Turn the ignition key ON, push the radio power button and the audio button. Record the radio presets. Turn off all lights and accessories.





2. Turn ignition key OFF and remove the key.
3. Remove auxiliary battery cover.





4. Disconnect the negative (-) terminal from the auxiliary battery. To prevent damage to the battery terminal, loosen the cable nut and raise the terminal straight up without twisting or prying the cable.
5. Remove the R/F door scuff plate and cowl side trim (See Figure 1).
6. Fold the carpet back towards the passenger seat.
7. Unbolt and remove the ECU Bracket (See Figure 1).
8. Unbolt and remove the HV ECU. Carefully remove the wire harness protector and unplug the electrical connectors from the HV ECU. Peel the (plastic) ECU Cover off the HV ECU (See Figure 1).
9. Unscrew and remove the HV ECU mounting brackets.
10. Screw the mounting brackets onto the new HV ECU. Install the (plastic) ECU Cover.
11. Carefully plug each electrical connector and install the wire harness protector.
12. Install the HV ECU and torque the mounting nuts.
Torque: 52 lbf-in (6.0 N-m, 60 kgf-cm).

13. Install the ECU Bracket. Torque the mounting bolts and nuts.
Torque: 52 lbf-in (6.0 N-m, 60 kgf-cm).

14. Roll out the carpet and install the front door scuff plate and cowl side trim.
15. Connect the negative (-) battery terminal and tighten the cable nut.
Torque: 52 lbf-in (6.0 N-m, 60 kgf-cm).

16. Remove the positive (+) battery terminal cover.
17. Connect the 12 volt charger SST (P/N 00002 YA121 01) to the auxiliary battery. Red charger clamp to the positive (+) terminal and the black charger clamp to the negative (-) battery terminal.





18. Plug the charger into a grounded 110V nominal outlet and verify the RED "POWER" light is on. Push the charger current toggle switch to the 10 amp position. Ensure the yellow light is on.

B. HV immobilizer Key Code Registration Procedure:

1. Ensure the parking brake is applied and the running mode selector lever is in "P. "
2. Insert the ignition key and turn the ignition switch to the ON position. Leave the vehicle in this condition for at least 30 minutes.
3. After a minimum of 30 minutes has elapsed, turn the ignition key OFF.
4. Unplug the charger from the 110V outlet. Remove the red and black charger clamps from the battery.
5. Install the battery positive (+) terminal cover.
6. Install the auxiliary battery cover.





7. Turn and hold the ignition switch to "Start" until the green "READY" indicator light remains on and steady while depressing the brake pedal. Then release the ignition key.
8. Ensure no trouble lights are illuminated on the Instrument panel or Multi Information display (MID).
9. Preset all recorded radio stations. Push the radio power button and the audio button. Tune to desired station, press and hold until a beep is heard. Repeat for each station, FM1, FM2, and AM.
10. Reset clock to current time.








REPAIR TIME:

NOTE:
Issue of this 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.
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