O2 sensor TOYOTA PRIUS 2001 Service Workshop Manual

2001 PRIUS (EWD414U)
M OVERALL ELECTRICAL WIRING DIAGRAM
1
234
23 PRIUS(
Cont. next page)
5
3 1
2
5A AM1
A12H
D 1 C 1B1
120A MAIN1I15
IGNITION SW100 A DC/ DC
4 AM1
ST1IG1 ACC
2
2B 3 2D 6
IDCowl si de
panel LH 2K 8 1B 2
W±B W±B
B±Y W± GW
B WB±GJ11
JUNCTI ON
CONNECTOR BATTERYF18
FUSI BLE L I NK
BLOCK NO. 2IG1
RELA Y
F11 F12,
FUSI BLE LI NK
BL OCK NO. 1BCF13, D
10A GAUGE
2A 5
W±G
15A DOME
1J 722 A 21 A 13 A 20 A 12 A
14A 2A3A1A 7B6B1B9A 11ABUZZER2B 3B
D OORHEAD
Combination M eter Power Source
2A 4
2B 7
2G 2
2A 6 G
A
G
A G
B
G
B
2A 7
2B 6
IHRight kick
panel51
See Illumination
System< 8±4>
LL±YSee Back±Up
Light System< 6±3> See ABS System
< 19±4> See EMPS Syst em
< 20±4>
15 A
2J 62J82J916 A 9B
7. 5A ECU±B
2C 5
BR L L L L
R± GL V± W LL
L
L
L Y Y± B BR±R GR±B GR ±B
From
Navigation
ECU< 1 4±5 >
R± G R± G
GR GR± L
GR V±W
V±W
V± W
J27 J28,
JUNCTION
CONNECTORAB Fr om Engine
Control
Module< 2±13>From Hybr id
Vehicle Control
ECU< 1±19> F
F
J27
J UNCTI ON
CONNE CTOR BODY ECUB A B 8 B 9, F16
FUEL SENDER
E10
E NGI NE CONT ROL
MODUL E
G 1
GATEWAY ECUA 7
A/ C AMPL I FI ER
13 14 11
4 4
11MPX + MPD1 MP X2 MPX 1 MPD2
MPX ±
C10 C11,
COMBINATION METERAB 4IP15IP1L±WL±Y
48516
3
H 8
OD O/ TRI P SW
[ HA ZARD WARNI NG SW] VFD
TC ODO EA G
From Mul ti
Di spl ay
< 14±7> V± W
MP X+ MP X± B
FU± FU+ FUA
19 11 20
BR±R
Y± B
Y
L±Y
L±R
FUEL SENDER SENSOR

2001 PRIUS (EWD414U)
M
78
6 5
(
Cont. next page)
24 PRIUS (
Cont' d)
9B 18B
4IE1 5IE1
4IK1 5IK1 A
B
C
EA
B
C
2F 615 A 16 A
11 A 4 A 5 B4B13 D 14 D 23 C
3D 22D 18BIA25
1 2
F2B 6C 5C17 C 15 C 16 C 14 C 13 C
6 II1 8 II1 7 II1 9 II1 10 II1
M 20 C C18 19 C 22 C 21 C
M DD
Air Conditioning
B A
A/ C AMPLI FI ER, A 8 A 7 A 9, C4C 1B 3C 1C 2C2 1
1 2 18
34
1 211
1422
12345 12345 B±R
G±W
G
R±L
L±O
B± LGR± LW±G
BRW±G
BR± WB± R
G±W
G
R±L
GR± B GRGR± BLG P±G R±WW
W W W
W± L BR±W
W± L BR±W
W±L BR± W V± YW W W W
W
W
W W W
W
W
W
W± R BR±YY±RL BR±R
B 8
BODY ECUA
E 8 E 9,
ENGI NE CONTROL MODULEBC
A10
A/ C ROOM
TEMP. SENSOR A12
A/ C THERMI STOR
Fr om FAN NO. 1 and
FA N NO. 2 Rel ay< 22± 4>
LOCK SGLOCK CF S5TS TS SGTPI S5 TPI TPI AI F AI R S5 TP SGTP TP AMC AMHMP X+ MP2 + NE A CTRF TR SGTR TE SGTE
A 2
A/C MAGNETIC
CLUTCH AND
L OCK SENSORMP X+ MPD2 MPX 1 MPX 2 TA M
MP X± MPD1 NEO A CT E 2
GR
, DE10 A 6
AMBI ENT
TEMP.
SENSOR
A11
A/C SOLAR
SENSOR C11
COMBINATION
METE RG 1
GATE WAY
ECU
IK12
Fr om FAN NO. 3 Rel ay
< 22±4>
A1 5
AI R MI X CONTROL SE RVO MOTOR A1 4
AI R I NLE T CONTROL S ERVO MOTOR IDH
Y
10 A
Fr om Conv erter
< 1±13>
MP X+ MPX ± HRLY

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.

ENGINE ± 1NZ-FXE ENGINE
171EG07
182EG07
Crankshaft Position
Sensor RotorOil HolePin
No.5 Journal
Balance Weight
No.1 Journal 48
4. Connecting Rod

The connecting rods are made of high-strength
material for weight reduction.

The connecting rod cap is held by bolts tight-
ened to plastic region.
5. Crankshaft

The crankshaft has 5 journals and 4 balance weights.

A crankshaft position sensor rotor has been pressed into the crankshaft to realize an integrated configura-
tion.

The surface roughness of the pins and journals have been improved for low-friction operation.

The bearing width has been reduced for low-friction operation.

ENGINE ± 1NZ-FXE ENGINE
171EG09
VVT-i ControllerTiming ChainExhaust Camshaft
Intake Camshaft
Chain Guide Chain Tension ArmChain Tensioner
171EG10
Exhaust Camshaft
Timing Rotor
Intake Camshaft
VVT-i Controller49
VALVE MECHANISM
1. General
Each cylinder has 2 intake valves and 2 exhaust valves.
The valves are directly opened and closed by 2 camshafts.
The intake and exhaust camshafts are driven by a roller timing chain.
The VVT-i system is used to improve fuel economy, engine performance and reduce exhaust emission.
2. Camshafts
In conjunction with the adoption of the VVT-i system, an oil passage is provided in the intake camshaft
in order to supply engine oil to the VVT-i system.
A VVT-i controller has been installed on the front of the intake camshaft to vary the timing of the intake
valves.
The timing rotor is provided behind the intake camshaft to trigger the camshaft position sensor.

ENGINE ± 1NZ-FXE ENGINE
182EG12
A ± A Cross Section Throttle Control Motor
AA
Throttle Position SensorReturn Spring
Opener Spring
182EG13
Vacuum Port55
INTAKE AND EXHAUST SYSTEM
1. Throttle Body

The adoption of the ETCS-i has realized excellent throttle control.

The ISC system and cruise control system are controlled comprehensively by the ETCS-i.

The ETCS-i, which drives the throttle valve through a DC motor that is controlled by the ECM, thus doing
away with a throttle link to connect the accelerator pedal to the throttle valve, has been adopted.

The throttle control motor is provided with a return spring that closes the throttle valve.

An opener spring is provided on the throttle position sensor side. This spring opens the throttle valve slight-
ly when the engine is stopped to prevent the throttle valve from sticking and to improve the engine's restart-
ability.

A warm coolant passage is provided below the throttle body to prevent the throttle valve from freezing
during cold temperatures.
2. Intake Manifold

Because it is not necessary to improve the in-
take air efficiency through inertial intake due to
the adoption of the Atkinson cycle, the length
of the intake pipe of the intake manifold has
been shortened, and furthermore, the intake
pipes for cylinders #1 and #2, as well as for #3
and #4, have been integrated midstream to
achieve a large-scale weight reduction.
In addition, the throttle body has been oriented
downflow in the center of the surge tank to
achieve a uniform intake air distribution.

A vacuum port has been provided for the Toyo-
ta HC adsorber and catalyst system.

ENGINE ± 1NZ-FXE ENGINE
182EG19
Air CleanerIntake Air Chamber
VSV (for EVAP)
ECM
VSV (for Purge Flow
Switching Valve)
Charcoal Canister
Vapor Pressure
Sensor
VSV (for Canister Closed Valve) Fuel Inlet Pipe Fuel: Vapor
: Fuel59
4. ORVR System
The ORVR (On-Board Refueling Vapor Recovery) is a system that uses a charcoal canister, which is provided
onboard, to recover the fuel vapor that is generated during refueling. This reduces the discharge of fuel vapor
into the atmosphere.
5. Fuel Tank
General
To reduce the amount of fuel vapor generated when the vehicle is parked, during refueling, or while driv-
ing, a vapor reducing fuel tank system has been adopted.
This system provides a vapor reducing fuel tank that expands or contracts in accordance with the volume
of the fuel in the fuel storage area in the fuel tank. By thus reducing the space in which fuel can evaporate,
the generation of fuel vapor is minimized.
Along with the provision of the vapor reducing fuel tank whose size fluctuates in the fuel tank, the fuel
gauge and the fuel pump have been provided in the sub tank. For this reason, a direct-acting fuel gauge
has been adopted.
NOTE:At low ambient temperatures, the capacity of the vapor reducing fuel tank is reduced as it is
made of resin (When the outside temperature is at ±10C (14F) the size of the tank will be re-
duced by approximate 5 liters).

ENGINE ± 1NZ-FXE ENGINE
165EG25
Camshaft
Position
Sensor
Crankshaft
Position
Sensor
Various
SensorsG2
NEECM
IGT1
IGT2
IGT3
IGT4
IGF+BIgnition Coil
(with Igniter)
No.1
Cylinder
No.2
Cylinder
No.3
Cylinder
No.4
Cylinder61

IGNITION SYSTEM
1. General
A DIS (Direct Ignition System) has been adopted. The DIS improves the ignition timing accuracy, reduces
high-voltage loss, and enhances the overall reliability of the ignition system by eliminating the distributor.
The DIS in 1NZ-FXE engine is an independent ignition system which has one ignition coil (with igniter) for
each cylinder.
2. Ignition Coil
The DIS provides 4 ignition coils, one for each cylinder. The spark plug caps, which provide contact to the
spark plugs, are integrated with an ignition coil. Also, an igniter is enclosed to simplify the system.
3. Spark Plug
Iridium-tipped spark plugs have been adopted to realize a 60,000-mile (100,000 km) maintenance-free op-
eration. Their center electrode is made of iridium, which excels in wear resistance. As a result, the center
electrode is made with a smaller diameter and improved the ignition performance.

CHARGING AND STARTING SYSTEM
MG1 and MG2 (Motor Generator No.1 and 2) have been adopted in the charging system, and the convention-
al generator has been discontinued.
Furthermore, due to the adoption of MG1 for the starting system, the conventional starter has been discontin-
ued.

ENGINE ± 1NZ-FXE ENGINE62
ENGINE CONTROL SYSTEM
1. General
The engine control system for the 1NZ-FXE engine has following system.
System
Outline
SFI
Sequential Multiport
Fuel InjectionAn L-type SFI system directly detects the intake air volume with a hot-wire
type mass air flow meter.
ESA
Electronic Spark
AdvanceIgnition timing is determined by the ECM based on signals from various
sensors. The ECM corrects ignition timing in response to engine knocking.
VVT-i
Variable Valve
Timing-intelligentControls the intake camshaft to an optimal valve timing in accordance with
the engine condition.
ETCS-i
Electronic
Throttle Control
System-intelligentOptimally controls the throttle valve opening in accordance with the ECM,
and the conditions of the engine and the vehicle, and comprehensively
controls the ISC and cruise control system.
Fuel Pump Control
Fuel pump operation is controlled by signal from the ECM.

To stop the fuel pump during operation of the SRS airbag.
Oxygen Sensor Heater
ControlMaintains the temperature of the oxygen sensors at an appropriate level to
increase accuracy of detection of the oxygen concentration in the exhaust gas.
Evaporative Emission
Control

The ECM controls the purge flow of evaporative emissions (HC) in the
charcoal canister in accordance with engine conditions.

Using 3 VSVs and a vapor pressure sensor, the ECM detects any
evaporative emission leakage occurring between the fuel tank and the
charcoal canister, and vapor reducing fuel tank through the changes in the
tank pressure. For details, see page 79.
Toyota HCAC System
The ECM controls the VSV (for Toyota HCAC System) to improve the clean
emission performance of the exhaust gas when the temperature of the TWC
is low. For details, see page 58.
Air Conditioning
Cut-Off ControlBy turning the air conditioning compressor OFF in accordance with the
engine condition, drivability is maintained.
Cooling Fan ControlRadiator cooling fan operation is controlled by signals from ECM based on
the engine coolant temperature sensor signal (THW).
HV Immobiliser
Prohibits fuel delivery, ignition, and starting the HV system if an attempt is
made to start the HV system with an invalid ignition key. For details, see page
80.
DiagnosisWhen the ECM detects a malfunction, the ECM diagnoses and memorizes
the failed section.
Fail-SafeWhen the ECM detects a malfunction, the ECM stops or controls the engine
according to the data already stored in memory.

ENGINE ± 1NZ-FXE ENGINE
No.4 INJECTOR
SPARK PLUGS
No.2 INJECTOR
No.1 INJECTOR
No.3 INJECTOR SENSORS ACTUATORS
SFI
#10
CRANKSHAFT POSITION
SENSORNE
CAMSHAFT POSITION
SENSORG2
THROTTLE POSITION SENSORVTA
VTA2
COMBINATION METER
SPD

Vehicle Speed Signal
HEATED OXYGEN SENSOR
(Bank 1, Sensor 1)OX1A
HEATED OXYGEN SENSOR
(Bank 1, Sensor 2)OX1B
AMBIENT TEMP. SENSORTA M
ESA
IGT1

IGT4
IGF
THROTTLE CONTROL
MOTORETCS-i
M
ECM
ENGINE COOLANT TEMP.
SENSORTHW
INTAKE AIR TEMP. SENSORTHA
MASS AIR FLOW METERVG
IGNITION SWITCHIGSW
KNOCK SENSORKNK1
OIL PRESSURE SWITCHMOPS
CAMSHAFT TIMING OIL
CONTROL VALVE OCV
VVT-i
Bank 1, Sensor 2
Bank 1, Sensor 1HT1A
HT1B
#20
#30
#40
OXYGEN SENSOR HEATER
CONTROL
HEATED OXYGEN SENSOR
HEATER
CIRCUIT OPENING RELAYFUEL PUMP CONTROLFC
IGNITION COIL
with IGNITER
63
2. Construction
The configuration of the engine control system in the INZ-FXE engine is shown in the following chart.
(Continued)