TOYOTA PRIUS 2001 Service Repair Manual

D09923
D09720
D08186
D09718
(b)
(a)
D09717
HT±40
± HYBRID TRANSAXLEHYBRID TRANSAXLE ASSEMBLY
2001 PRIUS (RM778U)
20. SET HYBRID TRANSAXLE ASSEMBLY
Set the hybrid transaxle assembly as shown in the illustration.
21. REASSEMBLE PARKING LOCK SHAFT ASSEMBLY
(a) Install the parking lock lever No. 3 to the parking lock
shaft.
(b) Using a pin punch and a hammer, drive in the pin.
(c) Turn the spacer and the lever shaft to align the small hole
in the spacer with the staking position mark on the lever
shaft.
(d) Using a pin punch, stake the spacer through the small
hole.
(e) Check that the spacer does not turn.
22. INSTALL PARKING LOCK SHAFT ASSEMBLY AND
WASHER
(a) Apply ATF to the parking lock shaft.
(b) Apply MP grease to the parking lock lever No. 3.
(c) Install the washer to the parking lock shaft assembly.
23. INSTALL PARKING LOCK SHAFT ASSEMBLY

D09887
SST
D09888
FIPG
± HYBRID TRANSAXLEHYBRID TRANSAXLE ASSEMBLY
HT±41
2001 PRIUS (RM778U)
(a) Using SST and a hammer, install a new oil seal to the
parking shaft cover.
SST 09950±60010 (09951±00230), 09950±70010
(09951±07100)
(b) Coat the lip of the oil seal with MP grease.
(c) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the parking
shaft cover and MG2 case.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing grooves.

Thoroughly clean all components to remove all the
loose material.

Using a non±reusable solvent, clean both sealing
surfaces.
(d) Apply FIPG to the parking shaft cover as shown in the il-
lustration.
FIPG:
Part No. 08826 ± 00090, THREE BOND 1281
or equivalent

Install a nozzle that has been cut to a 1.5 mm (0.06
in.) opening.

Parts must be assembled within 10 minutes after
application. Otherwise the material must be re-
moved and reapplied.

Remove the nozzle from the tube and reinstall the
cap.

D09715
D09889
FIPG
D09714
HT±42
± HYBRID TRANSAXLEHYBRID TRANSAXLE ASSEMBLY
2001 PRIUS (RM778U)
(e) Install the 5 bolts and parking shaft cover.
Torque: 13 N´m (130 kgf´cm, 10 ft´lbf)
NOTICE:
When installing the cover, be careful not to damage the lip
of the oil seal.
24. INSTALL MOTOR WATER JACKET COVER
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the motor
water jacket cover and MG2 case.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing grooves.

Thoroughly clean all components to remove all the
loose material.

Using a non±reusable solvent, clean both sealing
surfaces.
(b) Apply FIPG to the motor water jacket cover as shown in
the illustration.
FIPG:
Part No. 08826±00080 or equivalent

Install a nozzle that has been cut to a 1.5 mm (0.06
in.) opening.

Parts must be assembled within 10 minutes after
application. Otherwise the material must be re-
moved and reapplied.

Remove the nozzle from the tube and reinstall the
cap.
(c) Apply liquid sealer to 2 or 3 threads of the bolt end.
Sealant:
Part No. 08833 ± 00080, THREE BOND 1344, LOCTITE
242 or equivalent
(d) Install the motor water jacket cover with the 6 bolts.
Torque: 5.5 N´m (56 kgf´cm, 49 in.´lbf)

D09735
D09713
D09890
FIPG
± HYBRID TRANSAXLEHYBRID TRANSAXLE ASSEMBLY
HT±43
2001 PRIUS (RM778U)
25. INSTALL HOUSING TUBE
(a) Apply liquid sealer to 2 or 3 threads of the housing tube
end.
Sealant:
Part No. 08833 ± 00080, THREE BOND 1344, LOCTITE
242 or equivalent
(b) Install the housing tube.
Torque: 15 N´m (152 kgf´cm, 11 ft´lbf)
26. INSTALL PARKING COVER
(a) Install the detent spring and detent spring cover with the
bolt.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
(b) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the parking
cover and MG2 case.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing grooves.

Thoroughly clean all components to remove all the
loose material.

Using a non±reusable solvent, clean both sealing
surfaces.
(c) Apply seal packing to the parking cover as shown in the
illustration.
FIPG:
Part No. 08826 ± 00090, THREE BOND 1281 or equiva-
lent

Install a nozzle that has been cut to a 1.5 mm (0.06
in.) opening.

Parts must be assembled within 10 minutes after
application. Otherwise the material must be re-
moved and reapplied.

Remove the nozzle from the tube and reinstall the
cap.

D09712
D09725
D09724
D09723
O±Ring
D09722
HT±44
± HYBRID TRANSAXLEHYBRID TRANSAXLE ASSEMBLY
2001 PRIUS (RM778U)
(d) Install the parking cover with the 6 bolts.
Torque: 5.5 N´m (56 kgf´cm, 49 in.´lbf)
27. INSTALL OIL PUMP
(a) Apply ATF to individual sliding parts.
(b) Install the oil pump drive shaft.
(c) Install the oil pump driven rotor and drive rotor.
(d) Install a new O±ring without twisting it..
(e) Apply liquid sealer to 2 or 3 threads of the bolt end.
Sealant:
Part No. 08833 ± 00080, THREE BOND 1344, LOCTITE
242 or equivalent
(f) Install the oil pump cover with the 5 bolts.
Torque: 5.5 N´m (56 kgf´cm, 49 in.´lbf)

D09721
D09710
D09733
D09895
D09932
± HYBRID TRANSAXLEHYBRID TRANSAXLE ASSEMBLY
HT±45
2001 PRIUS (RM778U)
(g) Install a new O±ring to the plug.
(h) Install the plug.
Torque: 7.35 N´m (75 kgf´cm, 65 in.´lbf)
28. INSTALL WIRING HARNESS CONNECTOR (MG2 side)
Install the 2 wiring harness connectors with the 2 bolts.
Torque: 5.5 N´m (56 kgf´cm, 49 in.´lbf)
29. INSTALL WIRING HARNESS CONNECTOR (MG1 side)
Install the wiring harness connector with the bolt.
Torque: 5.5 N´m (56 kgf´cm, 49 in.´lbf)
30. INSTALL 4 WATER JACKET UNIONS
(a) Apply liquid sealer to 2 or 3 threads of the union end.
Sealant:
Part No. 08833 ± 00080, THREE BOND 1344, LOCTITE
242 or equivalent
(b) Install the 4 water jacket unions.
Torque: 50 N´m (510 kgf´cm, 37 ft´lbf)
31. INSTALL HIGH±VOLTAGE CABLE
(a) Install the high±voltage cable with the 3 bolts.
Torque: 18 N´m (183 kgf´cm, 13 ft´lbf)

D09933
D09891
FIPG
D09731
HT±46
± HYBRID TRANSAXLEHYBRID TRANSAXLE ASSEMBLY
2001 PRIUS (RM778U)
(b) Apply liquid sealer to 2 or 3 threads of the bolt end.
Sealant:
Part No. 08833 ± 00080, THREE BOND 1344, LOCTITE
242 or equivalent
(c) Install the 3 bolts.
Torque: 5.5 N´m (56 kgf´cm, 49 in.´lbf)
(d) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the power
cable cover and MG1 case.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing grooves.

Thoroughly clean all components to remove all the
loose material.

Using a non±reusable solvent, clean both sealing
surfaces.
(e) Apply FIPG to the power cable cover as shown in the il-
lustration.
FIPG:
Part No. 08826 ±00090, THREE BOND 1281 or equiva-
lent

Install the nozzle that has been cut to a 1.5 mm
(0.06 in) opening.

Parts must be assembled within 10 minutes after
application. Otherwise the material must be re-
moved and reapplied.

Remove the nozzle from the tube and reinstall the
cap.
(f) Install the power cable cover with the 4 bolts.
Torque: 4.8 N´m (48 kgf´cm, 42 in.´lbf)

D09709
± HYBRID TRANSAXLEHYBRID TRANSAXLE ASSEMBLY
HT±47
2001 PRIUS (RM778U)
32. INSTALL MOUNTING BRACKET
(a) Apply liquid sealer to 2 or 3 threads of the bolt end.
Sealant:
Part No. 08833 ± 00070, THREE BOND 1324 or
equivalent
(b) Install the mounting bracket with the 3 bolts.
Torque: 52 N´m (530 kgf´cm, 38 ft´lbf)

HT00J±02
D09790
HT±54
± HYBRID TRANSAXLESHIFT LOCK SYSTEM
2001 PRIUS (RM778U)
INSPECTION
1. INSPECT SHIFT POSITION SENSOR
(a) Remove the steering column upper cover and lower cov-
er.
(b) Disconnect the shift position sensor connector.
(c) Check continuity between terminals shown below when
the shift lever is moved to each position
Shift PositionTerminal No. to continuityTerminal No. to continuity
P1 ± 23 ± 8 ± 9
R1 ± 43 ± 8 ± 9
N1 ± 53 ± 8 ± 9
D1 ± 63 ± 8 ± 9
B1 ± 73 ± 8 ± 9
(d) Connect the shift position sensor connector.
(e) Install the steering column upper cover and lower cover.

D09785
SLS+
STPACC IGA
E B
P1
P
P2
SLS±KLS+
D09783
D09784
± HYBRID TRANSAXLESHIFT LOCK SYSTEM
HT±55
2001 PRIUS (RM778U)
2. INSPECT SHIFT LOCK CONTROL ECU
Using a voltmeter, measure the voltage at each terminal.
HINT:
Do not disconnect the ECU connector.
TerminalMeasuring ConditionVoltage (V)
A, 1 ± A, 5 (ACC ± E)Ignition switch ACC10 ± 14
A, 3 ± A, 5 (IG ± E)Ignition switch ON10 ± 14
A, 6 ± A, 5 (STP ± E)Depressing brake pedal10 ± 14
A, 4 ± A, 5 (KLS+ ± E)
5. Ignition switch ACC and P position
6. Ignition switch ACC and except P position
7. Ignition switch ACC and except P position (After approx. 1 second)0
7.5 ± 11
6 ± 9.5
B, 1 ± B, 5 (SLS+ ± SLS±)
1. Ignition switch ON and P position
2. Depress brake pedal
3. Except P position0
8 ± 13.5
0
B, 2 ± B, 4 (P1 ± P)1. Ignition switch ON, P position and depress brake pedal
2. Shift except P position under conditions above0
9 ± 13.5
B, 6 ± B, 4 (P2 ± P)1. Ignition switch ACC, P position
2. Shift except P position under conditions above9 ± 13.5
0
3. INSPECT SHIFT LOCK SOLENOID
(a) Disconnect the solenoid connector.
(b) Using an ohmmeter, measure the resistance between ter-
minals.
Standard resistance: 29 ± 35 W
If the resistance value is not as specified, replace the solenoid.
(c) Apply battery positive voltage between terminals. Check
the operation.
If the solenoid does not operate, replace the solenoid noise can
be heard from the solenoid.