Service Campaign 24TC08 - 2023 Prius/Prius Prime built before Oct 2023

Discussion in 'Gen 5 Prius Main Forum' started by Hammersmith, Feb 8, 2025.

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  1. Hammersmith

    Hammersmith Senior Member

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    This one went out a week ago(Jan 30). It has to do with the fuel tank system and small vapor leaks from the filler cap. In the case of the Prius Prime, it's just a recalibration of the engine control computer. In the case of the Prius(and Corolla HV), it involves adding a clamp inside the fuel tank around the fuel filler pipe. I'm guessing, but it appears the fuel filler pipe might possibly have a bit of in/out play in certain circumstances. That movement might cause the filler pipe to not quite align properly and allow very small amounts of vapor to escape somehow.

    Note that this is NOT a safety recall. Even if the problem occurs, it's an annoyance at worst; it's not dangerous.

    If your Prius(not Prime) is affected by this campaign, you can be nice to your service techs by bringing your car in with minimal fuel in the tank. Because they have to reach into the tank to install the clamp, the first step in the directions is to drain the tank of fuel. Also, to access the fuel tank opening, they have to pull the rear seats out, so clean your car of all objects in the entire rear seat area.

    Prius Prime labor is given as 0.7 hours for the recalibration. Prius labor is 1.7 hours to install the clamp. The Prius part kit is 04004-33147, which includes the clamp, a new fuel tank gasket, and two new plastic locking hooks for the rear seat bottom(they almost always break when you pull up the rear seat).

    Dealer letter(which includes a sample owner letter) and technical instructions are attached.


    I happened to fill my tank a few hours before I discovered the service campaign, so I plan to give my dealership a call in a week or two once my tank is around 1/4.
     

    Attached Files:

    #1 Hammersmith, Feb 8, 2025
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  2. RandyPete

    RandyPete Active Member

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    Timely and well presented. Thanks !
     
    #2 RandyPete, Feb 8, 2025
  3. Agent337

    Agent337 Member

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    Thanks for the detailed info. I just had this addressed last week along with my 15K service interval, nice to know exactly what was involved with the service campaign. Having a 2023 Prime, looks to be not too much! Thanks for sharing.
     
    #3 Agent337, Feb 8, 2025
  4. James mesiano

    James mesiano Junior Member

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    My 2023 just went in for its 20,000 service. they did not tell me about the filler neck recall they just did it. i was waiting 6 hours and i asked what is taking so long and then they told me. i was livid. the worst part after i waited 7 hours for the door recall and the filler neck recall and oil and etc. the next day the check engine light came on . the codes are " Evaporative emission control system Gross Leak!" and " Incorrect air flow" and incorrect purge flow" now i have to bring it back to the dealer. Never go to Glen Toyota in Fairlawn NJ.
     
    #4 James mesiano, Feb 12, 2025
  5. Tooly

    Tooly Member

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    Wonder if this applies in Canada? Taking my Prime in for a service and door recall next week, might as well add this to the list.
     
    #5 Tooly, Feb 14, 2025
  6. jojopuppyfish

    jojopuppyfish New Member

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    I have a Toyota Corolla but I got the same Service Notice as the OP.
    I want to thank the OP for all the details on this issue.
    I wish, however, that he put in all caps that DO NOT BRING YOUR CAR INTO THE DEALERSHIP UNTIL YOUR GAS LEVEL is 1/4 or less.
    The dealer, I think, spilled someone of it in the back of the car (or it smells like that)
    My tank was 3/4 filled and the dealer didn't warn me about this either.
    They said the smell will go away in a few days. If its still there after a week they told me to bring it back it.
    I made them check it twice to make sure everything was done correctly.
    Anyway, for those who surfed the internet and found this thread post, don't bring it into the dealer until you have 1/4 fuel or less in your car.
    They will take out the back seat to get to the fuel tank and if there is too much fuel it can spill.
    Thanks again to the OP who was helpful in the details on this issue.
     
    #6 jojopuppyfish, Mar 2, 2025
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  7. Uhcoustic

    Uhcoustic Member

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    Thank you for the detailed info! I just saw this service campaign.
     
    #7 Uhcoustic, Mar 2, 2025
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  8. Argyros

    Argyros Active Member

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    Took my car last weekend to get this TSB fixed...it took them 7 HOURS to fix it...at the 4 hour mark, which they said it would be done, they announced another 3 hours and offered a loaner car...because by the time we got back home and did our errands it would be time to turn around and go back- we decided to wait at the dealer. But 7 HOURS?? Oh and my gas tank was FULL
     
    #8 Argyros, Mar 4, 2025
  9. Argyros

    Argyros Active Member

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    Oh and the app still shows it not done, so I have to call them today....jeez!
     
    #9 Argyros, Mar 4, 2025
  10. Argyros

    Argyros Active Member

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    Oh and one more thing...its NOT the filter neck. It's the flange for the gas tank that needs to be replaced, hence why they have to take out the back seat.
     
    #10 Argyros, Mar 4, 2025
  11. Argyros

    Argyros Active Member

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    After looking at Hammersmith's diagram, it's BOTH the fuel filler neck AND the flange needing replacement, although it doesn't specify on the TSB...Sorry for the mis-information
     
    #11 Argyros, Mar 4, 2025
  12. Hammersmith

    Hammersmith Senior Member

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    Took about an hour for me. My appointment was for 10:15 and I drove away at 11:20. I figure the tech spent about 45min on the job.

    Not a perfect comparison as I did some prep work of removing the rear seats myself and telling the tech I'd replace them myself. Took me maybe 15min yesterday to remove, and I figure it will take me that long to reinstall once the temps rise back up again later this week. (I did it myself because I wanted to minimize the time spent waiting at the dealership, plus I hope to replace them at some point with the seats out of a Prime, so I wanted the practice.)

    I was also about 15 miles into my reserve fuel, so I don't think the tech had to drain anything from the tank before starting the job.
     
    #12 Hammersmith, Mar 4, 2025
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  13. Argyros

    Argyros Active Member

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    App still shows it's not done after 6 days...called on Mon and they said it would reset by Tues. What a load of crock. Gotta call them again today. UGH
     
    #13 Argyros, Mar 7, 2025
  14. Argyros

    Argyros Active Member

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    Called Toyota and spoke to the service manager...he claimed that although my app still says the recall is outstanding, they cannot do anything about it....its up to Toyota Corporate. Is there truth in that? He said that the recall was marked as completed and it's up to corporate to clear the app!!???
     
    #14 Argyros, Mar 8, 2025
  15. Mendel Leisk

    Mendel Leisk MMX GEN III

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    Maybe some of this description should be in the title? And to avoid it getting cumbersome, move some of the title to the opening sentence? Your call. Tideland could revise it.
     
    #15 Mendel Leisk, Mar 9, 2025
  16. Argyros

    Argyros Active Member

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    It all has to do with the recall...residual effect afterwards. Will post another thread on it to clarify.
     
    #16 Argyros, Mar 9, 2025
  17. CeruleanBlue

    CeruleanBlue Junior Member

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    Thanks for the clarification but still seens confusing. It's an efficiency thing if not safety?
     
    #17 CeruleanBlue, Mar 12, 2025
  18. Hammersmith

    Hammersmith Senior Member

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    I would say it's an emissions thing more than anything.

    One of the (many) ways you can get a check engine light is if your fuel cap doesn't form a tight seal. The code for that would be something like 'minor evap leak' or some such. Apparently there's some sort of flaw with the filler pipe/fuel tank interface where a fuel cap leak might not trigger the evap leak code. This clamp is supposed to fix that flaw. (Prius HEV version)

    It's not a safety issue because the amount of leakage almost certainly wouldn't ever be enough to ignite. But the federal regs are pretty strict on this stuff for smog reasons, so it had to be dealt with.

    I have no idea why the HEV needs a physical modification while the PHEV only needs a software update. Maybe because the fuel tanks are slightly different between models? (The FWD, AWD, and PHEV all have different tanks.)
     
    #18 Hammersmith, Mar 12, 2025
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  19. Need4Speed

    Need4Speed New Member

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    I have to disagree with one thing here. This should ABSOLUTELY be a safety issue. I had to have my car towed into the dealer because it reeked of fuel vapor both inside the cabin and outside the entire car! The tow truck driver smelled it immediately when he approached the vehicle and was like "wow!" The check engine light did come on. This was before the recall was issued and the dealer stated they smelled no fuel, re-tightened the gas cap, and turned off the light. Seriously?! They said it was safe to drive but it still smelled of fuel on warmer days. About 2 months later I get the recall notice in the mail. I was (am) so pissed! Hopefully it gets fixed correctly because it sounds like they are just putting a Band-Aid on the issue. Will this clamp last for the life of the car? Guess we'll see! They certainly don't make em' like they used to!
     
    #19 Need4Speed, Mar 12, 2025
  20. Ken789

    Ken789 Junior Member

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    Prius Prime here. Brought it in today after couldn't do the recalibration with routine service because tank was >1/4 full. Wondering if the need for the tank to be below 1/4 actually applies to the Prime since it's just a computer recalibration, not a physical repair to the gas tank?
     
    #20 Ken789, Mar 14, 2025
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