TOYOTA PRIUS 2001 Service Repair Manual

BO3SV±01
H15461
A
B
H15368
H15458
H15369
Hog Ring
BO±76
± BODYFRONT SEAT
2001 PRIUS (RM778U)
DISASSEMBLY
CAUTION:

When storing the seatback frame with the side airbag
assembly, do not face down the airbag deployment
side.

Never disassemble the side airbag assembly.
1. REMOVE HEADREST
2. REMOVE RECLINING RELEASE HANDLE
3. REMOVE SEAT CUSHION SHIELD
Remove the 2 screws and seat cushion shield as shown in the
illustration.
HINT:
Remove the seat cushion shield in order A, B as shown in the
illustration.
4. REMOVE FRONT SEAT INNER BELT
Remove the bolt and front seat inner belt.
5. REMOVE SEAT CUSHION INNER SHIELD
Remove the 2 screws and seat cushion inner shield.
6. w/o Side airbag:
REMOVE SEATBACK ASSEMBLY
Remove the 4 bolts and seatback assembly.
7. w/ Side airbag:
REMOVE SEATBACK ASSEMBLY
(a) Remove the clamp from wire harness of side airbag
installed under the seat, then pull out the wire harness.
(b) Remove the side airbag connector from the under the
seat.
(c) Remove the 4 bolts and seatback assembly.
8. w/o Side airbag:
REMOVE SEATBACK COVER
(a) Remove the hog rings.
(b) Remove the headrest supports.
(c) Remove the seatback cover with pad from the seatback
frame.
(d) Remove the seatback cover from the seatback pad.

H15413
H15370
Hog RingHog Ring
Hog Ring
H15371
± BODYFRONT SEAT
BO±77
2001 PRIUS (RM778U)
9. w/ Side airbag:
REMOVE SEATBACK COVER
(a) Remove the hog rings.
(b) Remove seatback cover hook.
(c) Remove the headrest supports.
(d) Remove the seat back cover with pad from the seatback
frame.
(e) Remove the seatback cover from the seatback pad.
10. REMOVE SEAT CUSHION COVER WITH PAD
(a) Remove the hog rings.
(b) Disengage the seat cushion cover hooks and remove the
seat cushion cover with pad from the seat cushion frame.
11. REMOVE SEAT CUSHION COVER
(a) Remove the hog rings.
(b) Remove the seat cushion cover from the seat cushion
pad.
12. REMOVE RECLINING ADJUSTER INSIDE COVERS
Remove the 2 screws and 2 reclining adjuster inside covers.
13. REMOVE SEAT TRACK HANDLE

BO3SW±01
H15371
H15370
Hog Ring
Hog Ring
Hog Ring
H15369
Hog Ring
H15413
± BODYFRONT SEAT
BO±79
2001 PRIUS (RM778U)
REASSEMBLY
NOTICE:
If the seatback frame with the side airbag assembly has
been dropped, or there are cracks, dents or other defects
in the case or connector of the side airbag assembly, re-
place the seatback frame with a new one.
1. INSTALL SET TRACK HANDLE
2. INSTALL RECLINING ADJUSTER INSIDE COVERS
Install the 2 screws and 2 reclining adjuster inside covers.
3. INSTALL SEAT CUSHION COVER
Install the seat cushion cover with new hog rings to seat cushion
pad.
HINT:
When installing hog rings, take care to prevent wrinkles as little
as possible.
4. INSTALL SEAT CUSHION COVER WITH PAD
Install the seat cushion cover with pad to the seat cushion frame
with new hog rings.
HINT:
When installing hog rings, take care to prevent wrinkles as little
as possible.
5. w/o Side airbag:
INSTALL SEATBACK COVER
(a) Install the seatback cover with new hog rengs to the seat-
back pad.
(b) Install the seatback cover with pad to the seatback frame
with new hog ring.
(c) Install the headrest supports.
6. w/ Side airbag:
INSTALL SEATBACK COVER
(a) Install the seatback cover with new hog rengs to the seat-
back pad.
(b) Install the seatback cover with pad to the seatback frame
with new hog rings.
(c) Install the seatback cover hook.
CAUTION:
Take care to hung the hook securely. Otherwise the seat
cover slides, it might cause incorrect deploying.

H15368
H15458
H15461
AB
BO±80
± BODYFRONT SEAT
2001 PRIUS (RM778U)
(d) Install the headrest supports.
7. w/o Side airbag:
INSTALL SEATBACK ASSEMBLY
Install seatback assembly with 4 bolts.
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
8. w/ Side airbag:
INSTALL SEATBACK ASSEMBLY
(a) Install the 4 bolts and seatback assembly.
(b) Install the side airbag connector from the under the seat.
(c) Install the clamp from wire harness of side airbag re-
moved under the seat.
9. INSTALL SEAT CUSHION INNER SHIELD
10. INSTALL FRONT SEAT INNER BELT
Install the front seat inner belt with the bolt.
Torque: 41 N´m (420 kgf´cm, 30 ft´lbf)
11. INSTALL SEAT CUSHION SHIELD
Install the 2 screws and seat cushion sushion shield as shown
in the illustration.
HINT:
Install the seat cushion shield in order A, B as shown in the il-
lustration.
12. INSTALL RECLINING RELEASE HANDLE
13. INSTALL HEADREST

BO3T5±01
BO0632
BO0633
45° 15° BO±88
± BODYSEAT BELT
2001 PRIUS (RM778U)
INSPECTION
CAUTION:
Replace the seat belt assembly (outer belt, inner belt, bolts,
nuts or sill±bar) if it has been used in a severe impact. The
entire assembly should be replaced even if damage is not
obvious.
1. RUNNING TEST (IN SAFE AREA)
(a) Fasten the front seat belts.
(b) Drive the car at 10 mph (16 km/h) and slam on the brakes.
Check that the belt locks and cannot be extended at this
time.
HINT:
Conduct this test in a safe area. If the belt does not lock, remove
the belt mechanism assembly and conduct the following static
check. Also, whenever installing a new belt assembly, verify the
proper operation before installation.
2. Driver 's seat belt (ELR):
STATIC TEST
(a) Make sure that the belt locks when pulled out quickly.
(b) Remove the locking retractor assembly.
(c) Tilt the retractor slowly.
(d) Make sure that belt can be pulled out at a tilt of 15 degrees
or less, and cannot be pulled out over 45 degrees of tilt.
lf a problem is found, replace the assembly.
3. Except driver's seat belt (ALR/ELR):
STATIC TEST
(a) Make sure that the belt locks when pulled out quickly.
(b) Remove the locking retractor assembly.
(c) Pull out the whole belt and measure the length of the
whole belt.
Then retract the belt slightly and pull it out again.
(d) Make sure that the belt cannot be extended further.
If a problem is found,replace the assembly.

N10070
Full Belt Length Minus
200 mm (7.87 in.)
BO0633
15°
45°
± BODYSEAT BELT
BO±89
2001 PRIUS (RM778U)
(e) Retract whole belt, then pull out the belt until 200 mm
(7.87 in.) of belt remains retracted.
(f) Tilt the retractor slowly.
(g) Make sure that the belt can be pulled out at a tilt of 15 de-
grees or less, and cannot be pulled out at over 45 degrees
of tilt.
lf problem is found, replace the assembly.

BO3T6±01
H13689
H13690
H13691
2 Clips
H13692
BO±90
± BODYSEAT BELT PRETENSIONER
1875 Author: Date:
2001 PRIUS (RM778U)
SEAT BELT PRETENSIONER
REMOVAL
NOTICE:

If the wiring connector of the seat belt pretensioner is
disconnected with the ignition switch at ON or ACC,
diagnostic trouble codes will be recorded.

Never use seat belt pretensioner from another ve-
hicle. When replacing parts, replace them with new
parts.
1. REMOVE FRONT DOOR INSIDE SCUFF PLATE
Using a screwdriver, remove the front door inside scuff plate.
HINT:
Tape the screwdriver tip before use.
2. REMOVE REAR DOOR INSIDE SCUFF PLATE
Using a screwdriver, remove the rear door inside scuff plate.
HINT:
Tape the screwdriver tip before use.
3. REMOVE FRONT DOOR OPENING TRIM
4. REMOVE REAR DOOR OPENING TRIM
5. REMOVE CENTER PILLAR LOWER GARNISH
Remove the center pillar lower garnish as shown in the illustra-
tion.
6. REMOVE FRONT SEAT OUTER BELT
(a) Using a screwdriver, remove the shoulder anchor cover.
HINT:
Tape the screwdriver tip before use.
(b) Remove the bolt and shoulder anchor.
(c) Using a screwdriver, remove the floor anchor cover.
HINT:
Tape the screwdriver tip before use.
(d) Remove the bolt and floor anchor.

H15467
H15471
± BODYSEAT BELT PRETENSIONER
BO±91
1876 Author: Date:
2001 PRIUS (RM778U)
(e) Driver's side:
Remove the retractor of front seat outer belt.
CAUTION:
Never disassemble the front seat outer belt.
NOTICE:
When removing the retractor of front seat outer belt, take
care not to pull the seat belt pretensioner wire harness.
(1) Disconnect the pretensioner connector as shown in
the illustration.
(2) Disconnect the tension reducer connector.
CAUTION:
When removing the seat belt pretensioner, work must be
started 90 seconds after the ignition switch is turned to the
ºLOCKº position and the negative (±) terminal cable is dis-
connected from the battery.
NOTICE:
When handling the pretensioner connector and tensionre-
ducer, take care not to damage the harness.
(3) Remove the bolts and retractor of front seat outer
belt.
(f) Except driver's side:
Remove the retractor of front seat outer belt.
CAUTION:
Never disassemble the front seat outer belt.
NOTICE:
When removing the retractor of front seat outer belt, take
care not to pull the seat belt pretensioner wire harness.
(1) Disconnect the pretensioner connector as shown in
the illustration.
CAUTION:
When removing the seat belt pretensioner, work must be
started 90 seconds after the ignition switch is turned to the
ºLOCKº position and the negative (±) terminal cable is dis-
connected from the battery.
NOTICE:
When handling the pretensioner connector and tensionre-
ducer, take care not to damage the harness.
(2) Remove the bolts and retractor of front seat outer
belt.

BO3T8±01
AB0152
SST
AB0158
SSTBattery
± BODYSEAT BELT PRETENSIONER
BO±93
2001 PRIUS (RM778U)
DISPOSAL
HINT:
When scrapping vehicles equipped with a seat belt pretension-
er or disposing of a front seat outer belt (with seat belt preten-
sioner) always first activate the seat belt pretensioner in accor-
dance with the procedure described below. If any abnormality
occurs in the seat belt pretensioner operation, contact the SER-
VICE DEPT. of the TOYOTA MOTOR SALES, USA, INC.
CAUTION:

Never dispose of the front seat outer belt which has
an inactivated pretensioner.

The seat belt pretensioner produces a sizeable ex-
ploding sound when it activates, so perform the op-
eration out±of±door and where it will not create a nui-
sance to nearby residents.

When activating the seat belt pretensioner, always
use the specified SST. (SRS Airbag Deployment Tool)
Perform the operation in a place away from electrical
noise.
SST 09082±00700

When activating a front seat outer belt (with seat belt
pretensioner), perform the operation at least 10 m (33
ft) away from the front seat outer belt.

The front seat outer belt (with seat belt pretensioner)
is very hot when the pretensioner is deployed, so
leave it alone for at least 30 minutes after deployment.

Use gloves and safety glasses when handling a front
seat outer belt with activated pretensioner.

Always wash your hands with water after completing
the operation.

Do not apply water, etc. to a front seat outer belt with
the activated pretensioner.
1. SEAT BELT PRETENSIONER ACTIVATION WHEN
SCRAPPING VEHICLE
HINT:
Have a battery ready as the power source to activate the seat
belt pretensioner.

AB0152
SST
AB0158
SSTBattery
H01580
SST
H15467H15471H16295
Driver's side:
Except driver's side:
BO±94
± BODYSEAT BELT PRETENSIONER
2001 PRIUS (RM778U)
(a) Check the functioning of SST.
CAUTION:
When activating the seat belt pretensioner, always use the
specified SST: SRS Airbag Deployment Tool.
SST
Driver's side: 09082±00700, 09082±00730
Except driver's side: 09082±00700, 09082±00740
(1) Connect the SST to the battery.
Connect the red clip of the SST to the battery posi-
tive (+) terminal and the black clip to the battery neg-
ative (±) terminal.
HINT:
Do not connect the yellow connector which will be connected
with the seat belt pretensioner.
(2) Press the SST activation switch, and check the LED
of the SST activation switch lights up.
CAUTION:
If the LED lights up when the activation switch is not being
pressed, SST malfunction is probable, so definitely do not
use the SST.
(3) Disconnect the SST from the battery.
(b) Disconnect the pretensioner connector.
Disconnect the pretensioner connector as shown in the
illustration.
NOTICE:
When handling the pretensioner connector, take care not
to damage the wire harness.
(c) Install the SST.
(1) Buckle the front seat belt and check that there is no
looseness and slack in the front seat inner belt and
front seat outer belt.