TOYOTA PRIUS 2001 Service Repair Manual

BO3QS±01
H15480
H15418
H15419
H15420
BO±26
± BODYLUGGAGE COMPARTMENT DOOR AND HINGE
2001 PRIUS (RM778U)
REMOVAL
1. REMOVE LUGGAGE COMPARTMENT DOOR TRIM
Remove the 10 clips and luggage compartment door trim.
2. REMOVE LUGGAGE COMPARTMENT DOOR LOCK
(a) Remove the 2 bolts and luggage compartment door lock.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
(b) Disconnect the link and cable from the lock.
3. REMOVE LUGGAGE COMPARTMENT DOOR OUTER
GARNISH
(a) Remove the 4 nuts.
(b) Remove the luggage compartment door outer garnish
and key cylinder.
4. REMOVE LICENCE PLATE LIGHT
(a) Disconnect the connector.
(b) Remove the licence plate light as shown in the illustration.
(c) Employ the same manner described above to the other
side.
(d) Using a clip remover, remove the clamps.
5. REMOVE LUGGAGE COMPARTMENT DOOR
Remove the 4 bolts luggage compartment door.
Torque: 8.3 N´m (85 kgf´cm, 74 in.´lbf)
6. REMOVE LUGGAGE REAR FLOOR FINISH PLATE
(a) Using a clip remover, remove the 4 clips.
(b) Remove the rear floor finish plate.
7. REMOVE LUGGAGE COMPARTMENT DOOR WEATH-
ERSTRIP

H13694
5 Clips
H15384
4 Clips
± BODYLUGGAGE COMPARTMENT DOOR AND HINGE
BO±27
2001 PRIUS (RM778U)
8. REMOVE LUGGAGE COMPARTMENT SIDE TRIM
COVER LH AND RH
(a) Remove the 3 clips and lower side luggage compartment
cover.
(b) Remove the clip and warning reflector holder.
(c) Remove the warning reflector box.
(d) Remove the 4 clips and luggage compartment side trim
cover LH and RH.
9. REMOVE REAR SEAT CUSHION (See page BO±83)
10. REMOVE REAR SEATBACK (See page BO±83)
11. REMOVE LUGGAGE TRIM NO. 2 COVER
12. REMOVE LUGGAGE COMPARTMENT TRIM COVER
13. REMOVE UPPER PART OF REAR DOOR OPENING
TRIMS
14. REMOVE ROOF SIDE INNER GARNISH
(a) Using a screwdriver, disengage the clips.
HINT:
Tape the screwdriver tip before use.
(b) Pull the garnish upward to remove it.
(c) Employ the same manner described above to the other
side.
15. REMOVE CRS TETHER ANCHOR
Remove the 3 CRS tether anchor covers and 3 CRS tether an-
chor brackets.
Torque: 20 N´m (200 kgf´cm, 14 ft´lbf)
16. REMOVE PACKAGE TRAY TRIM PANEL
(a) Pull the package tray trim panel upward to disengage the
clips.
(b) Remove the rear seat outer belts through the cut out on
the package tray trim.
(c) Pull the package tray trim panel forward to remove it.
17. REMOVE SILENCER PAD
18. REMOVE ROOM PARTITION PANEL
19. REMOVE TORSION BAR
(a) Remove the torsion bars from center bracket.

H15422
SST
H15423
SST
H15424
BO±28
± BODYLUGGAGE COMPARTMENT DOOR AND HINGE
2001 PRIUS (RM778U)
(b) Install SST to the torsion bar on the hinge side.
SST 09804±24010
(c) Push down on SST, and pull the luggage compartment
door hinge from the torsion bar.
(d) Slowly lift SST, and remove the torsion bar from the tor-
sion bar bracket with SST.
(e) Disconnect the torsion bar from the bracket.
(f) Employ the same manner described above to the other
side.
20. REMOVE LUGGAGE COMPARTMENT DOOR HINGE
Remove the pin and luggage compartment door hinge.

BO3PT±01
H15398
Matchmarks
H15396
± BODYFRONT WIPER AND WASHER
BO±35
2001 PRIUS (RM778U)
INSTALLATION
1. INSTALL WASHER NOZZLES
(a) Install the washer nozzles to the hood.
(b) Connect the washer hoses.
2. INSTALL OUTER FRONT COWL TOP PANEL
(a) Install the outer front cowl top panel with 6 bolts.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
(b) Push in the wiper motor wire harness with the grommet.
3. INSTALL ABS RELAY BLOCK
Install the ABS relay block with the 2 bolts.
4. INSTALL WIPER MOTOR
(a) Install the wiper motor with the 3 bolts to the wiper link.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
(b) Align the matchmarks on the wiper link and wiper motor,
then install the washer and nut.
Torque: 17 N´m (175 kgf´cm, 13 ft´lbf)
(c) Install the wiper motor cover.
5. INSTALL WIPER LINK ASSEMBLY
(a) Install the wiper link assembly with 5 bolts.
Torque: 7.4 N´m (75 kgf´cm, 65 in.´lbf)
(b) Connect the connecter.
6. INSTALL COWL TOP VENTILATOR LOUVERS
Install the cowl top ventilator louver LH and RH, then install the
2 screws.
7. INSTALL HOOD TO COWL TOP SEAL
8. INSTALL WIPER ARMS
(a) Operate the wiper motor once and turn the wiper switch
OFF.
(b) Install the wiper arms and tighten nuts by hand.

H15399Point Marks
BO±36
± BODYFRONT WIPER AND WASHER
2001 PRIUS (RM778U)
(c) Adjust the installation position of the arms to the positions
as shown in the illustration.
(d) Torque the 3 nuts.
Torque: 26 N´m (270 kgf´cm, 20 ft´lbf)
(e) Install the wiper arm head cap.

BO3PW±01
H13671
Primer M
Primer M
B
A
± BODYROOF DRIP SIDE FINISH MOULDING
BO±39
2001 PRIUS (RM778U)
INSTALLATION
1. CLEAN CONTRACT SURFACE OF BODY
(a) Using a heat light, heat the moulding surface to 40 ± 60
°C (104 ± 140 °F).
NOTICE:
Do not heat the body excessively.
(b) Using a knife, cut away any rough areas on the body.
NOTICE:
Be careful not to damage the body.
(c) Wipe off stains with cleaner.
2. CLEAN MOULDING
If reusing the moulding.
(a) Using a heat light, heat the moulding surface to 20 ± 30
°C (68 ± 86 °F).
NOTICE:
Do not heat the moulding excessively.
(b) Using a knife, cut the remaining adhesive from the mould-
ing.
NOTICE:
Be careful not to damage the moulding.
(c) Wipe off stains with cleaner.
3. COAT CONTACT SURFACE OF BODY WITH PRIMER
ºMº
Using a brush, coat the contact surface on the body with Primer
M as shown in the illustration.
Front end:
A: 24.9 mm (0.980 in.)
B: 47.5 mm (1.870 in.)
Rear end:
A: 23.2 mm (0.913 in.)
B: 57.5 mm (2.264 in.)
NOTICE:

Let the primer coating dry for 3 minutes or more.

Do not coat the adhesive.

Do not keep any of the opened Primer M for later use.

H13672
Adhesive
Adhesive
Primer M5.0 mm
(0.197 in.)
5.0 mm
(0.197 in.)
C
BO±40
± BODYROOF DRIP SIDE FINISH MOULDING
2001 PRIUS (RM778U)
4. APPLY ADHESIVE
(a) Cut off the tip of the cartridge nozzle.
Part No. 08850±00801 or equivalent
HINT:
After cutting off the tip, use all adhesive within the time de-
scribed in the chart below.
TemperatureTackfree time
35 °C (95 °F)15 minutes
20 °C (68 °F)100 minutes
5 °C (41 °F)8 hours
(b) Load the cartridge into the sealer gun.
(c) Apply adhesive to the hatched area in the illustration for
both front and rear of the vehicle.
C: 20 mm (0.79 in.)
HINT:
When removing the moulding, apply adhesive well to the part
where the body sealer is removed.
5. INSTALL MOULDING
Push the moulding to the body.
NOTICE:

Make sure that the body and moulding are heated to
the proper temperature.

Do not depress the adhesive coated parts excessive-
ly but just hold them down with your thumb.

Scrape off any overflowing adhesive with a plastic
spatula and clean the surface with a dry rag.

Take care not to drive the vehicle during the time de-
scribed in the chart below.
TemperatureMinimum time prior to driving the vehicle
35 °C (95 °F)1.5 hours
20 °C (68 °F)5 hours
5 °C (41 °F)24 hours

BO3PY±01
H13603
2 Clips
H15356
H15357
± BODYWINDSHIELD
BO±45
2001 PRIUS (RM778U)
REMOVAL
1. REMOVE FRONT PILLAR GARNISH AND NO. 1
FRONT PILLAR SPACERS
(a) Using a screwdriver, remove the front pillar garnish.
HINT:
Tape the screwdriver tip before use.
(b) Remove the 4 screws and 2 No. 1 front pillar spacers.
(c) Employ the same manner described above to the other
side.
2. REMOVE INNER REAR VIEW MIRROR
(a) Using a moulding remover, remove the cover as shown in
the illustration.
(b) Remove the 2 screws and inner rear view mirror.
3. REMOVE MAP LAMP
(a) Using a screwdriver, remove the map lamp.
(b) Disconnect the connector.
4. REMOVE SUN VISORS
Remove the 4 screws and pull the 2 sun visors downward.
5. REMOVE SUN VISOR HOLDERS
Remove the 2 screws and 2 holders.
6. REMOVE ASSIST GRIP
(a) Using a screwdriver, remove the caps.
HINT:
Tape the screwdriver tip before use.
(b) Remove the 2 screws and assist grip.
7. PULL DOWN FRONT PART OF ROOF HEADLINING
8. REMOVE WIPER ARMS
Remove the wiper arm head cap, 3 nuts and 2 wiper arms.
9. REMOVE HOOD TO COWL TOP SEAL
10. REMOVE COWL TOP VENTILATOR LOVERS
Remove the 2 screws, then pull out the cowl top ventilator lou-
ver RH and LH.

H15403
w/o Rain garter:
Body Windshield GlassWindshield Moulding
w/ Rain garter:
Windshield GlassWindshield Moulding
Body
BO5232
Protective Tape
Windshield
GlassBody
BO1689
Protective Tape Plastic Sheet
BO±46
± BODYWINDSHIELD
2001 PRIUS (RM778U)
11. REMOVE WINDSHIELD MOULDING
(a) Using a knife, cut off the moulding as shown.
NOTICE:
Do not damage the body with the knife.
(b) Remove the remaining moulding.
12. REMOVE WINDSHIELD GLASS
(a) Push piano wire through between the body and glass
from the interior.
(b) Tie both wire ends to wooden blocks or similar object.
HINT:
Apply protective tape to the outer surface to keep the surface
from being scratched.
NOTICE:
When separating the glass, be careful not to damage the
paint and interior and exterior ornaments. To prevent
scratching the safety pad when removing the windshield,
place a plastic sheet between the piano wire and safety
pad.

BO3PZ±01
BO4420
Body
Adhesive
BO5231
H15404
Stopper AA
H12696
a
a
a
a
b
b
a ± a b ± b
Along Datum Line
A
± BODYWINDSHIELD
BO±47
2001 PRIUS (RM778U)
INSTALLATION
1. CLEAN AND SHAPE CONTACT SURFACE OF BODY
(a) Using a knife, cut away any rough areas on the body.
HINT:
Leave as much of the adhesive on the body as possible.
(b) Clean the cutting surface of the adhesive with a shop rag
saturated in cleaner.
HINT:
Even if all the adhesive has been removed, clean the body.
2. CLEAN REMOVED GLASS
(a) Using a scraper, remove the damaged stoppers, dam and
adhesive sticking to the glass.
(b) Clean the glass with cleaner.
NOTICE:

Do not touch the glass face after cleaning it.

Be careful not to damage the glass.
3. INSTALL NEW STOPPERS
Install new stoppers onto the glass.
A: 9.5 mm (0.374 in.)
4. INSTALL NEW DAM
Install a new dam with adhesive tape as shown in the illustra-
tion.
A: 7.0 mm (0.276 in.)