O2 sensor TOYOTA PRIUS 2001 Service Repair Manual

IN0253
WRONG CORRECT
IN0252
WRONG CORRECT IN±6
± INTRODUCTIONREPAIR INSTRUCTIONS
6 Author: Date:
2001 PRIUS (RM778U)
(k) Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the prop-
er locations (See page IN±8).
Cancel the parking brake on the pedal place and
shift the transmission in N position.
When jacking up the front wheels of the vehicle at
first place stoppers behind the rear wheels.
When jacking up the rear wheels of the vehicle at
first place stoppers before the front wheels.
When either the front or rear wheels only should be
jacked up, set rigid racks and place stoppers in front
and behind the other wheels on the ground.
After the vehicle is jacked up, be sure to support it
on rigid racks . It is extremely dangerous to do any
work on a vehicle raised on a jack alone, even for
a small job that can be finished quickly.
(l) Observe the following precautions to avoid damage to the
following parts:
(1) Do not open the cover or case of the ECU unless
absolutely necessary. (If the IC terminals are
touched, the IC may be destroyed by static electric-
ity.)
(2) To disconnect vacuum hoses, pull off the end, not
the middle of the hose.
(3) To pull apart electrical connectors, pull on the con-
nector itself, not the wires.
(4) Be careful not to drop electrical components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not reused.
(5) When steam cleaning an engine, protect the elec-
tronic components, air filter and emission±related
components from water.
(6) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
(7) When checking continuity at the wire connector, in-
sert the tester probe carefully to prevent terminals
from bending.
(8) When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step±down
adapter for adjustment. Once the hose has been
stretched, it may leak air.

F08459
Marks
IN±22
± INTRODUCTIONFOR ALL OF VEHICLES
22 Author: Date:
2001 PRIUS (RM778U)
(3) Even in cases of a minor collision where the SRS
does not deploy, the steering wheel pad, front pas-
senger airbag assembly, side airbag assembly and
seat belt pretensioner should be inspected (See
page RS±14, RS±28, RS±63 and BO±92).
(4) Never use SRS parts from another vehicle. When
replacing parts, replace them with new parts.
(5) Before repairs, remove the airbag sensor if shocks
are likely to be applied to the sensor during repairs.
(6) Never disassemble and repair the airbag sensor as-
sembly, steering wheel pad, front passenger airbag
assembly, side airbag assembly or seat belt preten-
sioner.
(7) If the airbag sensor assembly, steering wheel pad,
front passenger airbag assembly, side airbag as-
sembly or seat belt pretensioner has been dropped,
or if there are cracks, dents or other defects in the
case, bracket or connector, replace them with new
ones.
(8) Do not directly expose the airbag sensor assembly,
steering wheel pad, front passenger airbag assem-
bly or seat belt pretensioner to hot air or flames.
(9) Use a volt/ohmmeter with high impedance (10 kW/V
minimum) for troubleshooting of the electrical cir-
cuit.
(10) Information labels are attached to the periphery of
the SRS components. Follow the instructions on the
notices.
(11) After work on the supplemental restraint system is
completed, check the SRS warning light (See page
DI±497).
(c) SPIRAL CABLE (in Combination Switch)
The steering wheel must be fitted correctly to the steering
column with the spiral cable at the neutral position, other-
wise cable disconnection and other troubles may result.
Refer to SR±14 of this manual concerning correct steer-
ing wheel installation.

± INTRODUCTIONFOR ALL OF VEHICLES
IN±27
27 Author: Date:
2001 PRIUS (RM778U)
(h) AIRBAG SENSOR ASSEMBLY
(1) Never reuse the airbag sensor assembly involved
in a collision when the SRS has deployed.
(2) The connectors to the airbag sensor assembly
should be connected or disconnected with the sen-
sor mounted on the floor. If the connectors are con-
nected or disconnected while the airbag sensor as-
sembly is not mounted to the floor, it could cause
undesired ignition of the supplemental restraint sys-
tem.
(3) Work must be started after 90 seconds from the
time the ignition switch is turned to the ºLOCKº posi-
tion and the negative (±) terminal cable is discon-
nected from the battery, even if only loosing the set
bolts of the airbag sensor assembly.
(i) WIRE HARNESS AND CONNECTOR
The SRS wire harness is integrated with the instrument
panel wire harness assembly. All the connectors in the
system are a standard yellow color. If the SRS wire har-
ness becomes disconnected or the connector becomes
broken due to an accident, etc., repair or replace it as
shown on page RS±66.

IN±28
± INTRODUCTIONFOR ALL OF VEHICLES
28 Author: Date:
2001 PRIUS (RM778U)
8. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER
CAUTION:
If large amount of unburned gasoline flows into the converter, it may overheat and create a fire haz-
ard. To prevent this, observe the following precautions and explain them to your customer.
(a) Use only unleaded gasoline.
(b) Avoid prolonged idling.
Avoid running the engine at idle speed for more than 20 minutes.
(c) Avoid spark jump test.
(1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible.
(2) While testing, never race the engine.
(d) Avoid prolonged engine compression measurement.
Engine compression tests must be done as rapidly as possible.
(e) Do not run engine when fuel tank is nearly empty.
This may cause the engine to misfire and create an extra load on the converter.
(f) Avoid coasting with ignition turned off.
(g) Do not dispose of used catalyst along with parts contaminated with gasoline or oil.
9. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM
For vehicles with mobile communication systems such as two±way radios and cellular telephones, observe
the following precautions.
(1) Install the antenna as far as possible away from the ECU and sensors of the vehicle's electronic
system.
(2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the ve-
hicle's electronic systems. For details about ECU and sensors locations, refer to the section on
the applicable component.
(3) Avoid winding the antenna feeder together with other wiring as much as possible, and also avoid
running the antenna feeder parallel with other wire harnesses.
(4) Check that the antenna and feeder are correctly adjusted.
(5) Do not install powerful mobile communications system.
10. FOR USING OBD II SCAN TOOL OR TOYOTA HAND±HELD TESTER
CAUTION:
Observe the following items for safety reasons:

Before using the OBD II scan tool or TOYOTA hand±held tester, the OBD II scan tool's instruc-
tion book or TOYOTA hand±held tester's operator manual should be read thoroughly.

Be sure to route all cables securely when driving with the OBD II scan tool or TOYOTA hand±
held tester connected to the vehicle. (i.e. Keep cables away from feet, pedals, steering wheel
and shift lever.)

Two persons are required when test driving with the OBD II scan tool or TOYOTA hand±held
tester, one person to drive the vehicle and the other person to operate the OBD II scan tool or
TOYOTA hand±held tester.

IN±32± INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
2001 PRIUS (RM778U)
2. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK
The diagnostic system in the PRIUS fulfills various functions. The first function is the Diagnostic Trouble
Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory
at the time of occurrence, to be output by the technician during troubleshooting. Another function is the Input
Signal Check which checks if the signals from various switches are sent to the ECU correctly.
By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can
be performed effectively. Diagnostic functions are incorporated in the following systems in the PRIUS.
SystemDiagnostic Trouble
Code CheckInput Signal Check
(Sensor Check)Diagnostic Test
Mode (Active Test)
Engine (with Check
Mode)
Hybrid Vehicle Control System
HV Battery Control System (with Check
Mode)
Anti±Lock Brake System With EBD & RBS
Electric Motor Power Steering
Supplemental Restraint System
Cruise Control System
Multiplex Communication System
Navigation System
Air Conditioning System

V07268
VIBRATION METHOD: When vibration seems to be the major cause.
CONNECTORS
WIRE HARNESS
PARTS AND SENSOR1
Slightly shake the connector vertically and horizontally.
Slightly shake the wire harness vertically and horizontally.
The connector joint, fulcrum of the vibration, and body
through portion are the major areas to be checked thorough-
ly.
Apply slight vibration with a finger to the part of the sensor
considered to be the problem cause and check that the mal-
function occurs.Shake Slightly
Swing Slightly
Vibrate Slightly
HINT:
Applying strong vibration to relays may result in open relays.
± INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN±35
2001 PRIUS (RM778U)
3. SYMPTOM SIMULATION
The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases,
a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and
environment in which the problem occurred in the customer's vehicle. No matter how much experience a
technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem
symptoms he will tend to overlook something important in the repair operation and make a wrong guess
somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the en-
gine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the prob-
lem can never be determined so long as the symptoms are confirmed with the engine hot condition or the
vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which
is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the ex-
ternal causes are applied to the vehicle in a stopped condition.
Important Points in the Symptom Simulation Test:
In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area
or parts must also be found out. To do this, narrow down the possible problem circuits according to the symp-
toms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation
test, judging whether the circuit being tested is defective or normal and also confirming the problem symp-
toms at the same time. Refer to the problem symptoms table for each system to narrow down the possible
causes of the symptom.

DTC No.
Indicates the diagnostic trouble code.

Page or Instructions
Indicates the page where the inspection procedure
for each circuit is to be found, or gives instructions
for checking and repairs.

Detection Item
Indicates the system of the problem or
contents of the problem.
Trouble Area
Indicates the suspect area of the
problem.
Mass Air Flow Circuit MalfunctionDetection Item

Open or short in mass air flow meter circuit

Mass air flow meter

ECM DTC No.
(See page)Trouble AreaMIL* MemoryP0100
(DI±24)
P0101
(DI±28)
P0115
(DI±33)
Open or short in intake air temp. sensor
circuit

Intake air temp. sensor

ECM Intake Air Temp. Circuit
Malfunction P0110
(DI±29)

Open or short in engine coolant temp. sensor circuit

Engine coolant temp. sensor

ECM
Throttle/ Pedal Position Sensor/Switch
ºAº Circuit MalfunctionEngine Coolant Temp.
Circuit Malfunction

Open or short in throttle position sensor circuit

Throttle position sensor

ECM
DTC CHART (SAE Controlled)
HINT:
Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument or other
factors.
If a malfunction code is displayed during the DTC check mode, check the circuit for that code listed in the table
below. For details of each code, turn to the page referred to under the ºSee pageº for the respective ºDTC No.º
in the DTC chart.
Mass Air Flow Circuit
Range/ Performance Problem
Mass air flow meter

Throttle position sensor Throttle/ Pedal Position Sensor/ Switch
ºAº Circuit Range / Performance Prob-
lem P0116
(DI±37)Engine Coolant Temp.
Circuit Range/ Performance Problem
Engine coolant temp. sensor

Cooling system
± INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN±37
2001 PRIUS (RM778U)
4. DIAGNOSTIC TROUBLE CODE CHART
The inspection procedure is shown in the table below. This table permits efficient and accurate troubleshoot-
ing using the diagnostic trouble codes displayed in the diagnostic trouble code check. Proceed with trouble-
shooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the
diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown below as an example.

V08423 Knock Sensor 1
GRECM
KNK
E1 12
E6
WIRING DIAGRAM
Wiring Diagram
This shows a wiring diagram of the circuit.
Use this diagram together with ELECTRICAL
WIRING DIAGRAM to thoroughly understand the
circuit.
Wire colors are indicated by an alphabetical code.
B = Black, L = Blue, R = Red, BR = Brown,
LG = Light Green, V = Violet, G = Green,
O = Orange, W = White, GR = Gray, P = Pink,
Y = Yellow, SB = Sky Blue
The first letter indicates the basic wire color and
the second letter indicates the color of the stripe.
DTC P0325Knock Sensor 1 Circuit Malfunction
CIRCUIT DESCRIPTION
Knock sensor is fitted to the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which
generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine
knocking occurs, ignition timing is retarded to suppress it.
DTC No. DTC Detecting Condition Trouble Area
P0325No knock sensor 1 signal to ECM with engine speed,
1,200 rpm or more.
Open or short in knock sensor1 circuit

Knock sensor 1 (looseness)

ECM
If the ECM detects the above diagnosis conditions, it operates the fall safe function in which the corrective retard angle
value is set to the maximum value.

Diagnostic Trouble Code No. and Detection Item

Circuit Description
The major role and operation, etc. of the circuit
and its component parts are explained.

Indicates the diagnostic trouble code, diagnostic
trouble code set parameter and suspect area of
the problem.


± INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN±39
2001 PRIUS (RM778U)
6. CIRCUIT INSPECTION
How to read and use each page is shown below.

V08425
LOCK
KNK
E6 Connector
(a) Remove the glove compartment (See page SF±68).
(b) Disconnect the E6 connector of ECM.
INSPECTION PROCEDURE
Replace knock sensor. 1 Check continuity between terminal KNK of ECM connector and body ground.
OK:
Check knock sensor (See page SF±61).Measure resistance between terminal KNK of ECM connector
and body ground.
Resistance: 1 MW or higher
Connector being checked is connected.
Indicates the condition of the connector of ECU during the check.
PREPARATION:
CHECK:
2Go to step 3.
OK OK
NG

Indicates the position of the ignition switch during the check.
Check from the connector back side.
(with harness)
Ignition Switch LOCK (OFF)
Ignition Switch START
LOCKIgnition Switch ON
Ignition Switch ACC
STARTON
ACC



Indicates the place to check the voltage or resistance.

Indicates the connector position to checked, from the front or back side.
Connector being checked is disconnected. Check from the connector front side. (without harness)
In this case, care must be taken not to bend the terminals.
E6 Connector KNKWire Harness
E6 Connector KNK
A00255 AB0117
A00265
Inspection Procedure
Use the inspection procedure to determine if
the circuit is normal or abnormal, and, if it is
abnormal, use it to determine whether the
problem is located in the sensors, actuators,
wire harness or ECU. IN±40
± INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
2001 PRIUS (RM778U)

FI0046
FI0047
FI0048
IN05X±14
± INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN±41
2001 PRIUS (RM778U)
HOW TO USE THE DIAGNOSTIC
CHART AND INSPECTION
PROCEDURE
1. CONNECTOR CONNECTION AND TERMINAL IN-
SPECTION

For troubleshooting, diagnostic trouble code charts or
problem symptom table are provided for each circuit with
detailed inspection procedures on the following pages.

When all the component parts, wire harnesses and con-
nectors of each circuit except the ECU are found to be
normal in troubleshooting, then it is determined that the
problem is in the ECU. Accordingly, if diagnosis is per-
formed without the problem symptoms occurring, refer to
Step 8 to replace the ECU. So always confirm that the
problem symptoms are occurring, or proceed with inspec-
tion while using the symptom simulation method.

The instructions ºCheck wire harness and connectorº and
ºCheck and replace ECUº which appear in the inspection
procedure, are common and applicable to all diagnostic
trouble codes. Follow the procedure outlined below
whenever these instructions appear.
OPEN CIRCUIT:
This could be due to a disconnected wire harness, faulty con-
tact in the connector, and a connector terminal pulled out, etc.
HINT:

It is rarely the case that a wire is broken in the middle of
it. Most cases occur at the connector. In particular, care-
fully check the connectors of sensors and actuators

Faulty contact could be due to rusting of the connector
terminals, to foreign materials entering terminals or a de-
formation of connector terminals. Simply disconnecting
and reconnecting the connectors once changes the
condition of the connection and may result in a return to
normal operation. Therefore, in troubleshooting, if no ab-
normality is found in the wire harness and connector
check, but the problem disappears after the check, then
the cause is considered to be in the wire harness or con-
nectors.
SHORT CIRCUIT:
This could be due to a contact between wire harness and the
body ground or to a short circuit occurred inside the switch, etc.
HINT:
When there is a short circuit between the wire harness and body
ground, check thoroughly whether the wire harness is caught
in the body or is clamped properly.