TOYOTA PRIUS 2001 Service Repair Manual

H15678
H15679Battery
SST
R13455
10 m (33 ft) or more
SSTBattery
H15680
± SUPPLEMENTAL RESTRAINT SYSTEMSIDE AIRBAG ASSEMBLY
RS±43
2001 PRIUS (RM778U)
(b) Disconnect the side airbag connector.
NOTICE:
When handling the airbag connector, take care not to dam-
age the airbag wire harness.
(c) Install the SST.
(1) Connect the connectors of the 2 SST to the airbag
connector.
SST 09082±00700, 09082±00750
NOTICE:
To avoid damaging the SST connector and wire harness,
do not lock the secondary lock of the twin lock.
(2) Move the SST at least 10 m (33 ft) away from the
front of the vehicle.
(3) Close all the doors and windows of the vehicle.
NOTICE:
Take care not to damage the SST wire harness.
(4) Connect the SST red clip to the battery positive (+)
terminal and the black clip to the battery negative
(±) terminal.
(d) Deploy the airbag.
(1) Check that no one is inside the vehicle or within 10
m (33 ft) area around the vehicle.
(2) Press the SST activation switch and deploy the air-
bag.
CAUTION:

The side airbag assembly is very hot when the airbag
is deployed, so leave it alone for at least 30 minutes
after deployment.

Use gloves and safety glasses when handling the
side airbag assembly with the deployed airbag.

Do not apply water, etc. to the side airbag assembly
with the deployed airbag.

Always wash your hands with water after completing
the operation.

When scrapping a vehicle, deploy the airbag and
scrap the vehicle with the side airbag assembly still
installed.

H15413
H15412
AB0163
Wire Harness
Diameter
Stripped Wire Harness Section
RS±44
± SUPPLEMENTAL RESTRAINT SYSTEMSIDE AIRBAG ASSEMBLY
2001 PRIUS (RM778U)
HINT:
The airbag deploys simultaneously as the LED of SST activa-
tion switch lights up.
2. DEPLOYMENT WHEN DISPOSING OF SIDE AIRBAG
ASSEMBLY
NOTICE:

When disposing of the side airbag assembly only,
never use the customer's vehicle to deploy the air-
bag.

Be sure to follow the procedure given below when de-
ploying the airbag.
HINT:
Have a battery ready as the power source to deploy the airbag.
(a) Remove the seatback assembly (See page RS±40).
(b) Disengage the hook of the seatback cover as shown in
the illustartion.
(c) Remove the 2 nuts and side airbag assembly from the
seatback assembly.
CAUTION:
When storing the side airbag assembly, keep the upper sur-
face of the airbag deployment side facing upward.
(d) Using a service±purpose wire harness, tie down the side
airbag assembly to the tire.
Wire harness: Stripped wire harness section
1.25 mm
2
or more (0.0019 in2. or more)
CAUTION:
If a wire harness which is too thin or some other thing is
used to tie down the side airbag assembly, it may be
snapped by the shock when the airbag is deployed. This is
highly dangerous. Always use a wire harness for vehicle
use which is at least 1.25 mm
2 (0.0019 in2.).

H15681
H15682
H15683
± SUPPLEMENTAL RESTRAINT SYSTEMSIDE AIRBAG ASSEMBLY
RS±45
2001 PRIUS (RM778U)
HINT:
To calculate the square of the stripped wire harness section±
Square = 3.14 x (Diameter)
2 divided by 4
(1) Install the 2 nuts to the side airbag assembly.
(2) Wind the wire harness around the stud bolts of the
side airbag assembly as shown in the illustration.
(3) Position the side airbag assembly inside the tire
with the airbag deployment direction facing inside.
Tire size: Must exceed the following dimensions±
Width: 185 mm (7.28 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:

Make sure the wire harness is tight. It is very danger-
ous when a loose wire harness results in the side air-
bag assembly coming free due to the shock from the
airbag deploying.

Always tie down the side airbag assembly with the
airbag deployment side facing inside.
NOTICE:
The tire will be marked by the airbag deployment, so when
disposing of the airbag use a redundant tire.

AB0158
SSTBattery
H01336
Tires
(5 or More)
R05403
H0133710 m (33 ft) or more SSTBattery
Side Airbag
Assembly
RS±46
± SUPPLEMENTAL RESTRAINT SYSTEMSIDE AIRBAG ASSEMBLY
2001 PRIUS (RM778U)
(e) Check functioning of the SST (See step 1±(a) on page
RS±16).
SST 09082±00700
(f) Place the tires.
(1) Place at least 2 tires under the tire to which the side
airbag assembly is tied.
(2) Place at least 2 tires over the tire to which the side
airbag assembly is tied. The top tire should have the
wheel installed.
(3) Tie the tires together with 2 wire harness.
CAUTION:
Make sure that the wire harness are tight. It is very danger-
ous when loose wire harness results in the tires coming
free due to the shock from the airbag deploying.
HINT:
Place the SST connector and wire harness inside tires. Secure
at least 1 m (3 ft) of slack for the wire harness.
(g) Install the SST.
Connect the connectors of the 2 SST to the side airbag
assembly connector.
SST 09082±00700, 09082±00750
NOTICE:
To avoid damaging the SST connector and wire harness,
do not lock the secondary lock of the twin lock. Also, se-
cure some slack for the SST wire harness inside the tire.
(h) Deploy the airbag.
(1) Connect the SST red clip to the battery positive (+)
terminal and the black clip to the battery negative
(±) terminal.
(2) Check that no one is within 10 m (33 ft) area around
the tire which the side airbag assembly is tied to.
(3) Press the SST activation switch and deploy the air-
bag.
HINT:
The airbag deploys simultaneously as the LED of the SST ac-
tivation switch lights up.

H00544
H00544
± SUPPLEMENTAL RESTRAINT SYSTEMSIDE AIRBAG ASSEMBLY
RS±47
2001 PRIUS (RM778U)
(i) Dispose of the side airbag assembly.
CAUTION:

The side airbag assembly is very hot when the airbag
is deployed, so leave it alone for at least 30 minutes
after deployment.

Use gloves and safety glasses when handling a side
airbag assembly with the deployed airbag.

Do not apply water etc. to a side airbag assembly with
the deployed airbag.

Always wash your hands with water after completing
the operation.
(1) Remove the side airbag assembly from the tire.
(2) Place the side airbag assembly in a vinyl bag, tie the
end tightly and dispose of it in the same way as oth-
er general parts disposal.
3. DEPLOYMENT WHEN DISPOSING OF SIDE AIRBAG
ASSEMBLY WITH AIRBAG DEPLOYED IN COLLISION
Dispose of the side airbag assembly.
CAUTION:

The side airbag assembly is very hot when the airbag
is deployed, so leave it alone for at least 30 minutes
after deployment.

Use gloves and safety glasses when handling a side
airbag assembly with the deployed airbag.

Do not apply water etc. to a side airbag assembly with
the deployed airbag.

Always wash your hands with water after completing
the operation.
(1) Remove the side airbag assembly from the seat
(See page RS±40 and see step 2).
(2) Place the side airbag assembly in a vinyl bag, tie the
end tightly and dispose of it in the same way as oth-
er general parts disposal.

RS0RB±01
H15368
H11975
H11974
H15461
± SUPPLEMENTAL RESTRAINT SYSTEMSIDE AIRBAG ASSEMBLY
RS±49
2001 PRIUS (RM778U)
INSTALLATION
NOTICE:
Never use airbag parts from another vehicle. When replac-
ing parts, replace them with new parts.
1. INSTALL SEATBACK ASSEMBLY
(a) Install the seatback assembly to the seat adjuster with the
4 bolts.
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
(b) Install 5 new hog rings.
HINT:
When installing the hog rings, take care to prevent wrinkles as
little as possible.
2. INSTALL SEAT CUSHION ASSEMBLY
Install the seat cushion assembly.
3. INSTALL FRONT SEAT CUSHION SHIELDS
(a) Install the inner front seat cushion shield with the 2
screws.
(b) Employ the same manner described above to the other
side.
4. INSTALL RECLINING ADJUSTER RELEASE HANDLE

H15460
RS±50
± SUPPLEMENTAL RESTRAINT SYSTEMSIDE AIRBAG ASSEMBLY
2001 PRIUS (RM778U)
5. INSTALL FRONT SEAT
NOTICE:
When mounting the seat to the vehicle, take care not to
damage the airbag wire harness.
(a) Connect the side airbag connector.
(b) Slide the front seat to the most front position.
NOTICE:
Make sure that seat adjuster locks.
(c) Without holding the seat track handle, mount the seat to
the vehicle.
HINT:
If holding the seat track handle, the adjusted rearmost position
slip off.
(d) Tighten the bolts on the front side temporarily, from the
bolt on the inner side tighten them completely.
Torque: 37 N´m (375 kgf´cm, 27 ft´lbf)
(e) Slide the seat to the most front position to install the bolts
on the rear side.
Torque: 37 N´m (375 kgf´cm, 27 ft´lbf)
(f) Install the 2 seat track covers.

BE0OM±08
± BODY ELECTRICALBODY ELECTRICAL SYSTEM
BE±1
1668 Author: Date:
2001 PRIUS (RM778U)
BODY ELECTRICAL SYSTEM
PRECAUTION
HINT:
Take care to observe the following precautions when performing inspections or removal and replacement
of body electrical related parts.
1. HEADLIGHT SYSTEM
Halogen bulbs have pressurized gas inside and require special handling. They can burst if scratched or
dropped. Hold a bulb only by its plastic or metal case.
Don't touch the glass part of a bulb with bare hands.
2. SRS (SUPPLEMENTAL RSTRAINT SYSTEM)
The PRIUS is equipped with an SRS (Supplemental Restraint System) such as the driver airbag, side airbag
and front passenger airbag. Failure to carry out service operation in the correct sequence could cause the
SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (in-
cluding removal or installation of parts, inspection or replacement), be sure to read the precautionary notices
in the RS section.

BE16S±02
BE±2
± BODY ELECTRICALTROUBLESHOOTING
1669 Author: Date:
2001 PRIUS (RM778U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
IGNITION SWITCH:
This system uses the multiplex communication system, so check diagnosis system of the multiplex commu-
nication system before you proceed with troubleshooting.
SymptomSuspect AreaSee page
Ignition switch is not set to each position.3. Ignition switch
4. Power source circuitBE±17
±
KEY UNLOCK WARNING SWITCH:
This system uses the multiplex communication system, so check diagnosis system of the multiplex commu-
nication system before you proceed with troubleshooting.
SymptomSuspect AreaSee page
Key unlock warning system does not operate.
(The buzzer sounds when the ignition key is ACC or ON)
1. Ignition Switch
2. Key Unlock Warning Switch
3. Wire Harness
4. Body ECU
5. Combination MeterBE±17
BE±17
±
±
±
HEADLIGHT AND TAILLIGHT SYSTEM:
This system uses the multiplex communication system, so check diagnosis system of the multiplex commu-
nication system before you proceed with troubleshooting.
SymptomSuspect AreaSee page
Auto turn±off system does not operate when the driver's door is
opened.1. Drivers Door Courtesy Switch
2. Body ECUBE±27
DI±678
Auto turn±off system:
Headlight and taillight do not come on.1. Body ECU
2. Wire HarnessDI±678
±
Auto turn±off system:
Headlight and taillight stay on.1. Body ECU
2. Wire HarnessDI±678
±
w/o Daytime Running Light System:
SymptomSuspect AreaSee page
Only one headlight comes on.1. Bulb
2. Wire Harness±
±
ºLO±Beamº does not light (All).1. Headlight Control Relay
2. Wire HarnessBE±20
±
ºLO±Beamº does not light (One side).
1. Bulb
2. HEAD LH Fuse
3. HEAD RH Fuse
4. Wire Harness±
BE±12
BE±12
±
ºHI±Beamº does not light (All).1. Headlight Dimmer Switch
2. Wire HarnessBE±20
±
ºHI±Beamº does not light (One side).
1. Bulb
2. HEAD LH Fuse
3. HEAD RH Fuse
4. Wire Harness±
BE±12
BE±12
±
ºFlashº does not light.
1. HEAD LH Fuse
2. HEAD RH Fuse
3. Headlight Dimmer Switch
4. Wire HarnessBE±12
BE±12
BE±20
±
ºFlashº does not light.1. Bulb
2. Wire Harness±
±

± BODY ELECTRICALTROUBLESHOOTING
BE±3
1670 Author: Date:
2001 PRIUS (RM778U) Headlight does not come on.
1. Headlight Control Relay
2. Wire HarnessBE±20
±
Headlight does not come on.1. Bulb
2. Wire Harness±
±
Headlight flickers.1. Bulb
2. Wire Harness±
±
Headlight is dark.1. Bulb
2. Wire Harness±
±
Only one taillight comes on.1. Bulb
2. Wire Harness±
±
Taillight does not come on.
(Headlight is normal)
1. TAIL Fuse
2. Taillight Control Relay
3. Light Control Switch
4. Wire HarnessBE±12
BE±42
BE±20
±
Taillight does not come on.
(Headlight does not light)1. Light Control Switch
2. Wire HarnessBE±20
±
w/ Daytime Running Light System:
SymptomSuspect AreaSee page
Only one headlight comes on.
1. Daytime Running Light Relay
2. Daytime Running Light Main Relay
3. Bulb
4. Wire HarnessBE±20
BE±20
±
±
ºLO±Beamº does not light (All).1. Headlight Control Relay
2. Wire HarnessBE±20
±
ºLO±Beamº does not light (One side).
1. Bulb
2. HEAD LO (LH) Fuse
3. HEAD LO (RH) Fuse
4. Wire Harness±
BE±12
BE±12
±
ºHI±Beamº does not light (All).
1. Headlight Dimmer Switch
2. Daytime Running Light Main Relay
3. Combination MeterBE±20
BE±20
±
ºHI±Beamº does not light (One side).
1. Bulb
2. HEAD HI (LH) Fuse
3. HEAD HI (RH) Fuse
4. Daytime Running Light No.2 Relay
5. Wire Harness±
BE±12
BE±12
BE±20
±
ºFlashº does not light.
1. Headlight Dimmer Switch
2. Daytime Running Light Main Relay
3. Wire HarnessBE±20
BE±20
±
Headlight does not come on.
1. Headlight Control Relay
2. Daytime Running Light Main Relay
3. Daytime Running Light No.2 Relay
4. Headlight Dimmer Switch
5. Light Control Switch
6. Body ECU
7. Wire Harness
8. BulbBE±20
BE±20
BE±20
BE±20
BE±20
DI±678
±
±
Headlight does not come on with light control switch in HEAD.
1. Light Control Switch
2. Body ECU
3. Wire HarnessBE±20
DI±678
±
Headlight does not go out with light control switch in OFF.
1. Headlight Control Relay
2. Body ECU
3. Wire HarnessBE±20
DI±678
±