In July 2015, Daihatsu & Toyota filed a statutory recall with Japan's Ministry of Land, Infrastructure, Transport and Tourism (MLIT) concerning the Hybrid control unit (inverter), covering the Prius Alpha, Mebius. The filing affects 342,401 vehicles manufactured between February 2011 and November 12, 2014.
Overview
| MLIT filing number | 1136040 |
|---|---|
| Type | Statutory Recall (government-mandated recall) |
| Date filed | July 15, 2015 |
| Manufacturer(s) | Daihatsu, Toyota |
| Component | Hybrid control unit (inverter) |
| Production period | February 2011 — November 12, 2014 |
| Vehicles affected | 342,401 units |
Filing in context
This notification is a joint filing by 2 manufacturers: Daihatsu & Toyota.
The Hybrid control unit (inverter) is the most frequently cited component category in this archive, appearing in 3 of its 4,890 filings. This filing is one of 12 Daihatsu notifications from 2015 in this archive. For scale, 140 of the 4,890 filings in this archive report a larger number of affected vehicles; the vehicles involved here were manufactured over a span of about 3 years and 9 months.
Defect
In the hybrid system, incorrect control software causes the boost circuit elements of the power converter (DC-AC inverter) to sustain damage from thermal stress. When this occurs, a warning light illuminates and the system enters fail-safe motor-only drive mode. If the element damage also generates electrical noise, the hybrid system shuts down entirely and the vehicle becomes inoperable.
Corrective action
On all vehicles, reprogram the control software to the corrected specification. If, after the software update, element damage causes a warning light to illuminate, the power converter module is replaced at no charge.
Affected models & chassis ranges
This filing lists 3 type code(s). A vehicle is affected if its chassis number falls within one of the ranges below.
| Type code (型式) | Model | Chassis ranges |
|---|---|---|
| DAA-ZVW40W | PRIUS ALPHA | ZVW40-0001002 — ZVW40-0014459; ZVW40-3000101 — ZVW40-3103239 |
| DAA-ZVW41N | MEBIUS | ZVW41-3251964 — ZVW41-3359095 |
| DAA-ZVW41W | PRIUS ALPHA | ZVW41-0001001 — ZVW41-0012638; ZVW41-3000101 — ZVW41-3359155 |
Original Japanese (MLIT source text)
Show the original Japanese filing text
状況
ハイブリッドシステムにおいて、制御ソフトが不適切なため、電力変換器（ＤＣ－ＡＣインバータ）の昇圧回路用素子が熱応力で損傷することがある。そのため、警告灯が点灯しフェールセーフのモータ走行となり、素子損傷時に電気ノイズが発生した場合には、ハイブリッドシステムが停止し、走行不能となるおそれがある。
改善措置
全車両、制御ソフトを対策仕様に修正する。 制御ソフト修正後に素子が損傷して警告灯が点灯した場合は、電力変換器のモジュールを無償交換する。
Source & verification
This entry reproduces public data from Japan's MLIT recall registry. English text is jdmvin.com's own translation; always verify against the official source:
https://renrakuda.mlit.go.jp/renrakuda/ris-detail-car.html?class=recalldatacar&id=3003562
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