TOYOTA PRIUS 2001 Service Repair Manual

NEW MODEL OUTLINE
MAIN MECHANISM
12
Low-emission & high-fuel efficiency.
TOYOTA hybrid system leading the way into the next
generation.
Tackling the challenge for high fuel efficiency and
low emissions
Prius - the mass-production gasoline hybrid vehicle - already meets all of the various strict emission levels
being proposed throughout the world, well ahead of the competition. What's more, through the use of the
hybrid system, surpassing fuel efficiency and a massive reduction in CO
2 has become a reality. The Prius
can truly be acclaimed as ªthe clean and environmentally friendly vehicle.º
Emission Reduction Features
1. Precision Emission Control
Through full utilization of the two Oxygen sensors, precision emission control is made possible even when
the engine is frequently stopped and re±started. Furthermore, excellent purification of exhaust gas is ensured
through the catalytic converter, resulting in reduced emissions.
2. Vapor Reducing Fuel Tank System
We have developed a new fuel tank system that can dramatically reduce the amount of fuel vapor generated
in the tank both when the vehicle is moving as well as when it is at a standstill. This system is the first one
in the world to be used.
3. TOYOTA HC Adsorber and Catalyst System
A new system has been adopted which adsorbs the HC that is emmitted between the time the engine is cold-
started and the catalytic converter is still cool and not yet activated, until the time the catalytic converter be-
comes active.
After the catalytic converter has been activated, the HC disassociates little by little and is then purified.
4. Adoption of a Thin-walled High-density Cell Catalytic Converter
In order to reduce the amount of time taken until the catalytic converter is activated, we developed a catalytic
chamber with a super thin ceramic wall. Also, high-density cells have been utilized as a measure to improve
strength and increase contact area with exhaust gas. Through these measures we have been able to achieve
a balance of reliability and purification efficiency.

NEW MODEL OUTLINE
Gasoline engine + AC motor = TOYOTA Hybrid System (THS)
Tremendous improvement in fuel efficiency & clean achieved!
Inverter1NZ-FXE
engine
P111 Hybrid transaxleHV battery182MO11182MO12
Hybrid transaxle
13
TOYOTA Hybrid System (THS)
The TOYOTA hybrid system has two drive sources, one is the gasoline engine and the other, the AC motor.
The power train system selects the best combination of the different characteristics of both depending on
driving conditions. Also, through the adoption of a regenerative braking system, which recovers energy
during deceleration and ªidling stopº whereby the engine is stopped during idling, we have been able to
provide for maximum energy conservation. This has resulted in a vastly superior fuel economy compared
with that of gasoline A/T vehicles of the same displacement.
Features of the System
1. Optimum distribution of drive sources
The most efficient engine operating zone is automatically selected by controlling the optimum distribution of the engine and motor
drive energy sources.
2. Reduced energy loss
The engine is automatically stopped when starting and travelling at low load to reduce fuel consumption.*1
The kinetic energy that used to be lost through engine or foot braking is recovered by the regenerative braking system and used
for recharging, thereby contributing to improved fuel efficiency. When the driver applies the brakes, the hydraulic and regenera-
tive braking systems are coordinated. In order to recover more energy, a higher proportion of regenerative braking is used.
3. Not required for recharging from an external source
The system uses MG1 (Motor Generator No.1) and MG2 (Motor Generator No.2) to maintain a constant battery charge, so unlike
an electric vehicle, recharging from an external source is not required.
*1 : In some cases, the engine does not stop, depending on the air conditioner and HV battery (Hybrid Vehicle Battery) status.
System configuration
P111 HYBRID TRANSAXLE
Fitted with built-in THS transaxle MG1 (Motor Generator No.1), MG2 (Motor Generator No.2), power spliting device and reduction
gears for the hybrid system. These function to switch engine operation to MG2 assistance, HV battery charging and power generation
for driving MG2.
Inverter
This controls the current between MG1, MG2 and HV battery and converts DC/AC power.
HV Battery (Hybrid Vehicle Battery)
This supplies power to the motor at full load or on engine stopping and stores power recovered by regenerative braking or power
generation by MG1. 228 nickel-metal hydride batteries are connected in series to obtain a voltage of 273.6 V DC.

NEW MODEL OUTLINE
MAIN MECHANISM
182MO13
182MO14
182MO15
182MO16
182MO17
14
THS operation
Starting and traveling at low load
When the engine efficiency is low such as when starting,
traveling at low load or the engine is stopped, permitting
travel by MG2; (however the engine may start under
SOC (State Of Charge) of the HV battery.)
Normal traveling
The engine energy is divided into two. One portion
directly drives the wheels. The other portion drives
MG1 to drive MG2 by generated power, which also
drives the wheels.
Full acceleration
In addition to the 2-way system for normal travelling,
the drive power of MG2 is further supplemented by the
power stored in the HV battery, resulting in powerful
and smooth acceleration.
Deceleration or braking
The wheels drive MG2 which acts as the generator for
regenerative power generation. The power recovered
by generation is stored in the HV battery.
Stopped
When the vehicle is stopped, the engine stops automat-
ically. However, when it is necessary to charge the HV
battery or to run the air conditioner compressor, the
engine will not stop.

NEW MODEL OUTLINE
182MO18
182MO19
182EG03
kW
60
50
40
30
20
10 N´m
120
11 0
100
90
80
Engine Speed (rpm) 1,000 2,000 3,000 4,000 5,000(52/4,500)
(111/4,200)
Torque
Output
15
HV Battery Charging
When high load operation is continued, the engine
does not stop to charge the HV battery even
if the vehicle is stopped, in order to keep the
HV battery charged to a given level. (when
ªREADYº light is ON.) ;however, the engine does
not charge the HV battery when the lever is
shifted into the ªNº position.
The engine speed may also be increased during normal
traveling in order to charge the HV battery.
1NZ-FXE Engine
The new Prius is fitted with a 1.5
gasoline engine which has been developed for the use with the TOYOTA
hybrid system. A mass of leading-edge technology has been implemented to achieve excellent fuel economy,
low emissions, light weight, compactness, and low vibration and noise.
Outline of the 1NZ-FXE Engine Engine performance curve
1NZ-FXE
Displacement (m
)1,497
TypeDOHC 4 valves
Bore y Stroke (mm)75.0 y 84.7
Compression ratio13.0
Maximum output [kW (HP)/rpm]52 (70)/4,500
Maximum torque [N´m (lb´ft)/rpm]111 (82)/4,200
FuelGasoline

NEW MODEL OUTLINE
MAIN MECHANISM
182CH29
16
4 Features of the 1NZ-FXE engine
1. Highly efficient and high expansion ratio gasoline engine
Adoption of a super fuel-efficient engine developed for use with THS. Its high expansion ratio cycle is achieved by applying the
Atkinson cycle*1 which obtains high thermal efficiency.
2. Reduction in frictional loss
The maximum engine speed is set at 4,500 rpm to reduce frictional resistance, thereby producing a highly efficient low-speed
engine.

An offset crankshaft with 12 mm deviation from the center axis of the cylinder bore is utilized to reduce frictional resistance
of the piston.

Frictional resistance is reduced through the use of low tension valve springs and piston rings.

Lightweight design has been adopted for reciprocating engine parts.
The above measures for reducing frictional loss contribute to improved fuel economy.
3. VVT-i (Variable Valve Timing -intelligent)
The timing of the opening and closing of the intake valves is controlled by the computer according to driving conditions, such
as engine speed and level of acceleration. Thus, smooth intake and exhaust are achieved to greatly improve torque in the low
and medium speed zones. This also contributes to better fuel economy and purification of exhaust gas. Then the VVT-i function
is used to reduce vibration when the engine starts.
4. Compact, lightweight, and low emission
Adoption of an aluminum cylinder block and compact design of parts. And, by positioning the catalytic converter near the engine
for a backwards exhaust layout, we have been able to reduce emissions when the engine is cold started.
*1 : Atkinson Cycle: Proposed by an English engineer named James Atkinson, this thermal cycle enables the compression stroke
and the expansion stroke of the mechanism to be set independently of each other.
Suspension
MacPherson strut type suspension with L-shape
lower arms has been adopted in the front and
torsion beam with toe control link suspension
in the rear. Also, each component part is opti-
mally located and tuned for both excellent con-
trollability and enhanced riding comfort.
EMPS (Electric Motor-assisted Power Steering)
System
Vehicle speed sensing type electric motor-assisted power steering is fitted as standard. Unlike conventional
hydraulic power steering, EMPS does not depend on an engine for its power source, providing a steering feel
in no way inferior to conventional steering when the engine has stopped. Thus it is suitable for the HV system.
Other merits include improved fuel economy through energy conservation, lighter weight, and no need to fill
the power steering fluid.

NEW MODEL OUTLINE
MAIN EQUIPMENT
182MO20
[Information Screen]
<Energy monitoring screen>This screen indicates the direction of energy trans-
mission. It is also possible to check the current drive
method (engine, motor or both) and status of power
generation by the engine and that of charging regen-
erative energy.
<Fuel consumption screen>This screen indicates the average fuel consumption,
amount of recovered energy and fuel consumption for
that moment. Average fuel consumption is displayed
at 5-minutes intervals. The recovered energy display
indicates the amount of energy recovered over the past
5 minutes, with each mark representing 50Wh.
182BE36
182BE37
17
A range of features for comfort - the more you use them,
the better they get.
Multi-Information Display

The 5.8º wide touch panel type multi-information color LCD
is standard.

Energy monitor, fuel consumption and other vehicle information
screens, audio operation status and audio operation screen can
be indicated on the multi-information display. The outside tem-
perature are also indicated on the screen.
[Audio system]

An AM/FM cassette and 4-speaker system compatible with the
multi-information display has been adopted.

As the touch panel type display is used to operate the audio sys-
tem, the multi-information display simultaneously indicates the
operating status of the audio system.

The antenna provided is a collapsible style pole antenna posi-
tioned at the center of the roof.
[GPS Voice Navigation]

A GPS (Global Positioning System) voice navigation system
is optional.

The multi-information display can show the map on favorite
type among turn list, arrow display and enlarged intersection.

Using DVD (Digital Versatile Disk) as a memory source for map
data, a large quantity of information can be processed.
 Main Function of the Multi-information Display
ScreenFunction
Enlargement / reduction, rotation and move-
ment of map
Mapscreen
Indication of current position and direction of
travel
Map screen
displayCorrection of current positiondis lay(option)Setting, change and indication of route()
Voice guidance
Indication of enlarged intersections
Memory and indication of map position
Audio screenStatus of audio equipment and audio opera-
tion screen indication
InformationEnergy monitor screen indicationInformationscreenFuel consumption screen indication
Adj t tSound quality adjustment screen indicationAdjustmentscreenImage quality adjustment screen indicationscreenNo indication
On-screenAudio status indicationOn screenindicationWarning indication
Interrupt screenWarning indication
DiagnosisscreenDisplays system diagnosisscreen
displayDisplays various types of coefficient settings

NEW MODEL OUTLINE
MAIN EQUIPMENT
182MO23(For U.S.A.)
Glove box Accesory box Multi-box
Front door pocket
Seat back pocket
(Driver's and
passenger seat)
182MO24182MO09
182MO25
Small storage box
Cup holder
(for two caps use)11.839ft3 (by SAE suitcase method)
luggage space is secured.182MO26182MO27182MO28
18
Air Conditioning
An automatic air conditioning has been adopted
in consideration to ease of use.

A clean air filter which removes pollen and
dust is included as a standard fitting for puri-
fying the air inside the cab.

Two air conditioning modes, A/C for eco-
nomical air conditioning and MAX for espe-
cially strong air conditioning, are provided.
Wireless Door Lock Remote Control System
With the wireless door lock remote control system, all the doors can be locked and unlocked by signals emitted
by the transmitter.
Power Window System
A power window system which enables all windows to be raised or lowered with switches has been adopted.
An auto up/down function and jam protection function have been added to the driver's power window.
HV Immobiliser System
HV immobiliser system will not allow the HV system to be started by duplicate key is used. This system
will permit the HV system to be started only when the ID code of the transponder chip impregnated in the
key matches the ID code registered beforehand in the transponder key amplifier.
Theft Deterrent System
When an attempt is made to forcibly enter the vehicle or open the hood or trunk lid without a key, or when
the battery terminals are removed and reconnected, this system sounds the horn and flashes the headlights,
taillights and emergency flashers for about 1 minute to alert the owner. At the same time, it locks all the
doors.
Storage Space
Ample storage space with an emphasis on practicality provided throughout the Prius.
Instrument panel (passenger seat)Seat back pocketFront door pocket
Center console boxLuggage space

NEW MODEL OUTLINE
SAFETY
182MO30182MO29
182MO31Side Impact Energy
19
Prius ± one step ahead of the rest even in the area of
safety.
Drive with the utmost peace of mind.
Passive Safety Body
The impact absorbing body adopted for the new Prius effectively absorbs and distributes the impact from
front and side collisions to ease the effects of the impact on the driver and passengers, and the high-strength
body structure minimizes deformation of the cabin itself.
[Frontal collision]
The front section of the body frame and under body absorb and
distribute the load generated by a frontal collision, while the strong
cabin frame eases the effect of the impact on the driver and passen-
gers and minimizes deformation of the cabin, thus realizing an ideal
body structure.
The front side member is of a straight design to be deformed
effectively from the front end. Also, in the event of a front
collision, the force of the impact is effectively distributed
to each of the braces and members through the sections
where they join the cabin.
[Side collision]
Along with the ideal body structure which effectively absorbs and distributes the load on the frame in side collisions, we have maintained
the strength of each pillar, rocker panel and door to minimize deformation of the cabin.

NEW MODEL OUTLINE
SAFETY
182MO32
Aluminum EA Material
EA : Energy Absorbing
EA rib
(center pillar garnish pad) EA rib
(side rail front specer)EA rib
(side rail rear specer)
20
Head Impact Protection Structure
The construction of the pillar trims and roof side adopted gives full consideration to protecting the heads of
the driver and passengers from injury in the event of a collision. In addition, impact absorbing material has
been built into the interior of each pillar trim and roof side which are most likely to be the cause of head
injuries in a collision.
SRS Airbag
SRS airbags are standard for the driver and front passenger seats on all models. In the event of a frontal collision,
the airbags function to support the seatbelts in reducing the impact to the driver and front passenger. Also,
SRS side airbags are available as a option. The SRS side airbags have been designed to help reducing the
impact energy that is transmitted to the driver and front passenger in the event of a side collision.
Seatbelt with Pre-tensioner and Force-limit-
ing Mechanism
Three-point type seatbelts with pre-tensioner and force limiter are standard on the front seats of all models.
An ELR-equipped seatbelt is provided on the driver's side and an ALR/ELR selectable one on the passenger
side.
Three sets of 3-point type
ALR/ELR selectable seatbelts are fitted on the rear seats.

CONCEPT
NEW MODEL OUTLINE 6
Introducing the Prius ± the car that is friendly to both
the earth and to people! ... and announcing of a new
feel of
future worth.
When we consider the future of the earth, this car was deemed to become a necessary part
of it.
A car that is unbelievably friendly and comfortable while still maintaining a high degree
of practicality...
The answer to this is the car we would like to present to you here ± the Prius.
A streamlined and artistic exterior design combined with a safety features that would make
anyone feel at ease.
What's more, through selecting the TOYOTA hybrid system which effectively utilizes 2
power sources ± electricity and gasoline ± we have been able to achieve world top-class
level fuel economy and low emissions.
TOYOTA is proud to present the ªHybrid Car Priusº as a car that is ideal for now and
well into the future as well.
The Prius leads the way in the showing direction that cars must go in the 21st century.
182IN01