TOYOTA PRIUS 2001 Service Repair Manual

BO0XI±05
± BODYSRS AIRBAG
BO±3
1788 Author: Date:
2001 PRIUS (RM778U)
SRS AIRBAG
PRECAUTION
The PRIUS is equipped with an SRS (Supplemental Restraint System) such as the driver airbag, front pas-
senger airbag and side 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
(including removal or installation of parts, inspection or replacement), be sure to read the precautionary no-
tices in the RS section.

BO3QK±01
H13682
H15388
Clip
H15389
: 2 Clips
H153907 Clips
± BODYFRONT DOOR
BO±11
2001 PRIUS (RM778U)
DISASSEMBLY
1. REMOVE INSIDE HANDLE BEZEL
(a) Using a screwdriver, open the screw cap.
HINT:
Tape the screwdriver tip before use.
(b) Remove the screw.
(c) Using a screwdriver, remove the inside handle bezel as
shown in the illustration.
HINT:
Tape the screwdriver tip before use.
2. REMOVE POWER WINDOW SWITCH
(a) Remove the screw.
(b) Using a screwdriver, remove the power window switch.
HINT:
Tape the screwdriver tip before use.
(c) Disconnect the connectors.
3. REMOVE LOWER FRAME BRACKET GARNISH
(a) Using a screwdriver, remove the lower frame bracket gar-
nish.
HINT:
Tape the screwdriver tip before use.
(b) Remove the front flame cover.
4. REMOVE DOOR TRIM
(a) Remove the clip.
(b) Insert a screwdriver between the door panel and door trim
to pry the trim out.
NOTICE:
Be careful not damage the door panel and trim.
HINT:
Tape the screwdriver tip before use.
(c) Pull the door trim upward to remove it.

H15391
H15392
H15393
Drill
BO±12
± BODYFRONT DOOR
2001 PRIUS (RM778U)
5. REMOVE INSIDE HANDLE
Remove the screw and inside handle, disconnect the 2 cables
from the inside handle as shown in the illustration.
6. REMOVE SERVICE HOLE COVER
(a) Remove the 2 screws and door trim No. 1 bracket.
(b) Remove the 2 grommets.
(c) Remove the service hole cover.
NOTICE:
Do not tear the cover.
HINT:

At the time of reassembly, please refer to the following
item.

Bring out the 2 control cables and wire harness through
the service hole cover.
7. REMOVE SPEAKER
(a) Disconnect the connecter.
(b) Using a drill of less then ù 4 mm (0.16 in), drill out the rivet
heads and remove the speaker.
(c) Gently and vertically put the drill to the rivet, and cut the
rivet flanges.
NOTICE:

Prizing the hole with a drill can lead to damage to the
rivet hole or breaking the drill.

Take cafe as the cut rivet is hot.
(d) Even if flange is taken off, continue drilling and push out
remaining fragments will the drill.
(e) Using a vacuum cleaner, remove the drilled rivet and their
dust from the inside of the door.

H15394
Air Riveter
H00475
Mandrel
H15395Protective Tape
H15408
H15407
± BODYFRONT DOOR
BO±13
2001 PRIUS (RM778U)
HINT:
At the time of reassembly, please refer to the following item.
Using an air riveter and nose piece No.1, strike rivets into the
door panel to install the speaker to the door panel.
NOTICE:
At the time of reassembly, please refer to the following
item.
If the rivet is not positioned perpendicularly it will bend the
mandrel. When the trigger is then pulled, it may damage the
air riveter.
8. REMOVE OUTSIDE VIEW MIRROR
(a) Disconnect the connecter.
(b) Remove the 3 nuts andout side view mirror.
Torque: 7.8 N´m (80 kgf´cm, 69 in.´lbf)
9. REMOVE DOOR BELT MOULDING
Using a scraper, remove the door belt moulding.
HINT:
Tape the scraper tip before use.
10. REMOVE DOOR LOCK SILENCER
11. REMOVE DOOR GLASS
(a) Remove the 3 bolts and reinforce inside extension.
(b) Open the door glass until the door belts appear in the ser-
vice hole.
(c) Remove the 2 bolts.
NOTICE:
Be careful not to drop the door glass.
(d) Pull the door glass upward to remove it.
12. REMOVE DOOR GLASS RUN
13. REMOVE LOWER FLAME
Remove the 2 nuts, plate and lower flame.

H15435
H15436
BO±14
± BODYFRONT DOOR
2001 PRIUS (RM778U)
14. REMOVE WINDOW REGULATOR
(a) Disconnect the connector.
(b) Remove the 2 bolts from the window regulator.
Torque: 4.9 N´m (50 kgf´cm, 43 in.´lbf)
(c) Remove the 4 bolts and window regulator.
Torque: 8.3 N´m (85 kgf´cm, 74 in.´lbf)
HINT:
At the time of reassembly, please refer to the following item.
Apply MP grease to the window regulator.
NOTICE:
At the time of reassembly, please refer to the following
item.
Do not apply grease to the spring of the window regulator.
15. REMOVE DOOR LOCK
(a) Disconnect the control cable from the clamp.
(b) Disconnect the 2 links from the outside handle and key
cylinder.
(c) Disconnect the connecter.
(d) Remove the bolt.
Torque: 4.9 N´m (50 kgf´cm, 43 in.´lbf)
(e) Remove the 3 screws and door lock.
Torque: 4.9 N´m (50 kgf´cm, 43 in.´lbf)
HINT:
At the time of reassembly, please refer to the following item.

Apply adhesive to the 3 screws.
Part No. 08833±00070, THREE BOND 1324 or equiva-
lent

H10815
± BODYFRONT DOOR
BO±15
2001 PRIUS (RM778U)

Apply MP grease to the sliding and rotating parts of the
door lock.
16. REMOVE OUTSIDE HANDLE
(a) Remove the 2 bolts and outside handle.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
(b) Remove the key cylinder from the handle.

BO3QO±01
H13682
H13683
Clip
H136842 Clips
H136857 Clips
± BODYREAR DOOR
BO±19
2001 PRIUS (RM778U)
DISASSEMBLY
1. REMOVE INSIDE HANDLE BEZEL
(a) Using a screwdriver, open the screw cap.
HINT:
Tape the screwdriver tip before use.
(b) Remove the screw.
(c) Using a screwdriver, remove the inside handle bezel as
shown in the illustration.
HINT:
Tape the screwdriver tip before use.
2. REMOVE POWER WINDOW SWITCH
(a) Remove the screw.
(b) Using a screwdriver, remove the power window switch.
HINT:
Tape the screwdriver tip before use.
(c) Disconnect the connector.
3. REMOVE REAR DOOR LOWER BRACKET GARNISH
Using a screwdriver, remove the rear door lower bracket gar-
nish.
HINT:
Tape the screwdriver tip before use.
4. REMOVE DOOR TRIM
(a) Remove the clip.
(b) Insert a screwdriver between the door panel and door trim
to pry the trim out.
NOTICE:
Be careful not to damage the door panel and trim.
HINT:
Tape the screwdriver tip before use.
(c) Pull the trim upward to remove it.

H15391
H15429
H15430Protective Tape
H15427
H15428
BO±20
± BODYREAR DOOR
2001 PRIUS (RM778U)
5. REMOVE INSIDE HANDLE
Remove the screw and inside handle, disconnect the 2 cables
from the inside handle as shown in the illustration.
6. REMOVE DOOR TRIM BRACKET NO. 1
Remove the 2 screws and door trim bracket, then remove the
2 grommets.
7. REMOVE SERVICE HOLE COVER
Remove the service hole cover.
NOTICE:
Do not tear the cover.
HINT:
At the time of reassembly, please refer to the following item.
Bring out the 2 control cables and wire harness through the ser-
vice hole cover.
8. REMOVE DOOR BELT MOULDING
Using a scraper, remove the door belt moulding.
HINT:
Tape the scraper tip before use.
9. REMOVE DOOR LOCK LINK SILENCER
10. REMOVE DOOR GLASS RUN
11. REMOVE WEATHERSTRIP
12. REMOVE DIVISION BAR
(a) Remove the 2 bolts and screw.
(b) Pull the division bar forward.
(c) Rotate the division bar 90° and pull it upward as shown
in the illustration.
13. REMOVE QUARTER WINDOW GLASS
(a) Remove the quarter window glass with the weatherstrip.
(b) Remove the weatherstrip from the quarter window glass.

H13687
H15431
H15432
H15433
± BODYREAR DOOR
BO±21
2001 PRIUS (RM778U)
14. REMOVE INSIDE PANEL PLATE
Remove the 3 screws and inside panel plate.
15. REMOVE INSIDE PANEL REINFORCEMENT
Remove the 4 screws and inside panel plate.
16. REMOVE DOOR GLASS
(a) Side out the door glass from the window regulator.
NOTICE:
Be careful not to drop the door glass.
(b) Pull the door glass upward to remove it.
17. REMOVE WINDOW REGULATOR
Disconnect the connector, then remove the 4 bolts and window
regulator.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
HINT:
Remove the regulator through the service hole.
HINT:
At the time of reassembly, please refer to the following item.
Apply MP grease to the window regulator.
18. REMOVE DOOR LOCK
(a) Remove the child protection cover.
(b) Disconnect the connector.
(c) Using a screwdriver, remove the door lock link guide and
clamp.
HINT:
Tape the screwdriver tip before use.
(d) Remove the 3 screws.
Torque: 4.9 N´m (50 kgf´cm, 43 in.´lbf)
HINT:
At the time of reassembly, please refer to the following item.
Apply adhesive to the 3 screws.
Part No. 08833±00070, THREE BOND 1324 or equiva-
lent
(e) Remove the bolts.
(f) Remove the door lock through the service hole.

H15434
BO±22
± BODYREAR DOOR
2001 PRIUS (RM778U)
HINT:
At the time of reassembly, please refer to the following item.
Apply MP grease to the sliding and rotating parts of the door
lock.
19. REMOVE OUTSIDE HANDLE
(a) Remove the 2 bolts.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
(b) Remove the outside handle and key cylinder.