engine TOYOTA PRIUS 2001 Service Repair Manual

IN0HK±02
B04759
B A
B13824
Engine Serial
NumberMotor Serial
Number
± INTRODUCTIONIDENTIFICATION INFORMATION
IN±3
3 Author: Date:
2001 PRIUS (RM778U)
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION AND
ENGINE AND MOTOR SERIAL
NUMBER
1. VEHICLE IDENTIFICATION NUMBER
The vehicle identification number is stamped on the vehicle
identification number plate and the certification label, as shown
in the illustration.
A: Vehicle Identification Number Plate
B: Certification Label
2. ENGINE AND MOTOR SERIAL NUMBER
(a) The engine serial number is stamped on the engine block,
as shown in the illustration.
(b) The motor serial numbers is stamped, as shown in the il-
lustration.

IN0253
WRONG CORRECT
IN0252
WRONG CORRECT IN±6
± INTRODUCTIONREPAIR INSTRUCTIONS
6 Author: Date:
2001 PRIUS (RM778U)
(k) Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the prop-
er locations (See page IN±8).
Cancel the parking brake on the pedal place and
shift the transmission in N position.
When jacking up the front wheels of the vehicle at
first place stoppers behind the rear wheels.
When jacking up the rear wheels of the vehicle at
first place stoppers before the front wheels.
When either the front or rear wheels only should be
jacked up, set rigid racks and place stoppers in front
and behind the other wheels on the ground.
After the vehicle is jacked up, be sure to support it
on rigid racks . It is extremely dangerous to do any
work on a vehicle raised on a jack alone, even for
a small job that can be finished quickly.
(l) Observe the following precautions to avoid damage to the
following parts:
(1) Do not open the cover or case of the ECU unless
absolutely necessary. (If the IC terminals are
touched, the IC may be destroyed by static electric-
ity.)
(2) To disconnect vacuum hoses, pull off the end, not
the middle of the hose.
(3) To pull apart electrical connectors, pull on the con-
nector itself, not the wires.
(4) Be careful not to drop electrical components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not reused.
(5) When steam cleaning an engine, protect the elec-
tronic components, air filter and emission±related
components from water.
(6) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
(7) When checking continuity at the wire connector, in-
sert the tester probe carefully to prevent terminals
from bending.
(8) When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step±down
adapter for adjustment. Once the hose has been
stretched, it may leak air.

IN0002
Example
± INTRODUCTIONREPAIR INSTRUCTIONS
IN±7
7 Author: Date:
2001 PRIUS (RM778U)
(m) Installation and removal of vacuum hose:
(1) When disconnecting vacuum hoses, use tags to
identify how they should be reconnected to.
(2) After completing a job, double check that the vacu-
um hoses are properly connected. A label under the
hood shows the proper layout.
(n) Bleeding of hydraulic brake booster system:
When repairing the hydraulic brake booster or ABS,
bleeding the air out of the hydraulic brake booster (See
page BR±4).
(o) Unless otherwise stated, all resistance is measured at an
ambient temperature of 20°C (68°F). Because the resis-
tance may be outside specifications if measured at high
temperatures immediately after the vehicle has been run-
ning, measurement should be made when the engine has
cooled down.

IN0HO±01
B04757
B04746
IN±10
± INTRODUCTIONFOR ALL OF VEHICLES
10 Author: Date:
2001 PRIUS (RM778U)
FOR ALL OF VEHICLES
PRECAUTION
1. PRECAUTIONS FOR HIGH±VOLTAGE CIRCUIT IN-
SPECTION AND SERVICE
(a) Engineers to be engaged in inspection and servicing re-
lated to high±voltage systems should undergo special
training.
(b) All the high±voltage wire harness connectors are colored
orange: the HV battery and other high±voltage compo-
nents are identified by the ºHigh Voltageº caution labels.
Do not carelessly touch these wires and components.
(c) Before inspecting or servicing the high±voltage system,
be sure to take measures such as wearing insulated
gloves and removing the service plug to prevent electro-
cution. Carry the removed service plug in your pocket to
prevent other technicians from reinstalling it while you are
servicing the vehicle.
(d) After removing the service plug, wait 5 minutes before
touching any of the high±voltage connectors and termi-
nals.
HINT:
The 5 minutes are required to discharge the high±voltage con-
denser inside the inverter.
(e) Before wearing insulated gloves, make sure that they are
not cracked, reptured, torn, or damaged in any other way.
Do not wear wet insulated gloves.
(f) When servicing the vehicle, do not wear a metal object
like a mechanical pencil or scale that may drop acciden-
tally and cause a short circuit.
(g) Before touching a bare high±voltage terminal, wear insu-
lated gloves and ensure that the terminal is not charged
with electricity (approx. 0 V) using an electrical tester.

B04747
± INTRODUCTIONFOR ALL OF VEHICLES
IN±11
11 Author: Date:
2001 PRIUS (RM778U)
(h) After disconnecting or exposing a high±voltage connec-
tor or terminal, insulate it immediately using insulation
tape.
(i) The screw of a high±voltage terminal should be tightened
firmly to the specified torque. Both insufficient and exces-
sive tightening torque can cause failure.
(j) Call other engineers' attention to the vehicle which high±
voltage system is being inspected or repaired by hanging
a ºHigh Voltage Operation in Progress. Do Not Touchº
sign (See the next page).
(k) After servicing the high±voltage system and before rein-
stalling the service plug, check again that you have not
left a part or tool inside, that the high±voltage terminal
screws are firmly tightened, and that the connectors are
correctly engaged.

B04748
B04749
1. +Terminal
2. +Terminal3. ±Terminal
4. ±Terminal
B04750
± INTRODUCTIONFOR ALL OF VEHICLES
IN±13
13 Author: Date:
2001 PRIUS (RM778U)
2. PRECAUTIONS TO BE OBSERVED WHEN INSPECT-
ING OR SERVICING ENGINE COMPARTMENT
The PRIUS, automatically turns the engine ON and OFF when
the ignition switch is set to the ON position provided that the
READY light on the instrument panel is it.
Before inspecting or servicing the engine compartment, there-
fore, remove the ignition switch key.
3. ACTIONS TO BE TAKEN WHEN BATTERIES ARE DE-
PLETED
(a) Actions to be taken when the auxiliary battery is depleted
HINT:
The following phenomena indicate that the auxiliary battery is
depleted:

No display appears on the instrument panel when you
turn the ignition switch to the ON position.

The hybrid system does not start.

The headlights are dark.

The sound from the horn is weak.
NOTICE:
Never use a quick charger.
(1) Move the shift lever to the P position, and engage
the parking brake.
(2) Remove the ignition key plate from the ignition
switch.
(3) Using a booster cable, connect the 12 V battery of
the rescue vehicle and auxiliary battery of the
stalled vehicle, as shown in the illustration.
(4) Start the engine of the rescue vehicle and run the
engine at a speed slightly higher than the idling
speed for 5 minutes to charge the auxiliary battery
of the stalled vehicle.
(5) Turn the ignition switch of the stalled vehicle to the
START position to start the hybrid system.
If the hybrid system fails to start and the master and HV battery
warning lights come on, the HV battery may have been dis-
charged.
(6) Disconnect the booster cable in the reverse way of
the connection procedure.
NOTICE:
If the auxiliary battery needs to be replaced, replace it only
with a 12 V battery specially designed for the use of the
PRIUS.

B04762
IN±14
± INTRODUCTIONFOR ALL OF VEHICLES
14 Author: Date:
2001 PRIUS (RM778U)
(b) Actions to be taken when HV battery is depleted
NOTICE:
Leaving a vehicle alone for 2 ± 3 months may cause electric
discharge from HV battery.
When this happens, replace the HV battery.
4. INSPECTION MODE
HINT:

The PRIUS automatically stops the engine while the ve-
hicle is stopped with the engine warmed up and battery
well charged if the A/C compressor operation is not re-
quired. Therefore, even if the vehicle stops for any reason
such as a check of ignition timing, the inspection mode
should be activated when continuous operation of the en-
gine is required.

The PRIUS has a skid control as traction control function.
When the wheel speed of the front wheels exceeds that
of the rear wheels, this function restrains the wheel speed
of the front wheels. It is necessary to activate the inspec-
tion mode and reset the skid control when turning only the
front wheels using a speedometer tester.
Activation inspection mode (Without using a hand±held tester)
(1) Perform the following (2) through (6) within 60 sec.
(2) Turn the ignition switch ON from OFF.
(3) With the shift lever in P position, fully depress the
accelerator pedal 2 times.
(4) With the shift lever in N position, fully depress the
accelerator pedal 2 times.
(5) With the shift lever in P position, fully depress the
accelerator pedal 2 times.
(6) Activate the inspecting mode and check that the hy-
brid system error warning light on the multi±center
display flashes.
(7) Turning the ignition switch to START starts the en-
gine's continuous operation.
NOTICE:

The idling speed in the inspection mode is approx.
1,000 rpm. The number of revolutions will increase up
to 1,500 rpm if the accelerator pedal is depressed to
a degree of less than 60%, and up to 2,250 rpm in a
case of 60% or more.

If a diagnosis code is recorded when entering the in-
spection mode, the master warning light and the error
warning light on the multi±center display is lit.

± INTRODUCTIONFOR ALL OF VEHICLES
IN±15
15 Author: Date:
2001 PRIUS (RM778U)

When the master warning light is lit during operation
in the inspection mode, deactivate the inspection
mode and inspect the diagnosed area.
HINT:
When continuous operation of the engine is required for such
as an exhaust leakage inspection, it is advisable as an easier
way to turn ON the FULL switch of the air conditioner.
5. SPECIAL NOTES FOR VEHICLE INSPECTION
(a) Vehicle conditions
(1) Before activating the service mode, turn the air con-
ditioner off, start the engine with the shift lever at P
position, and check that the engine stops within
several seconds after starting. (Engine warm up
check)
(2) Activate the service mode and inspect the vehicle.
The shift position for each test is as follows:
Test itemShift lever position
1. Vehicle straight traveling test (side
slip inspection)D
2. Braking force testN
3. Speedometer testD
4. Exhaust gas test (idling)P
5. Headlight testP
(3) Reset the service mode immediately after comple-
tion of inspection.
NOTICE:
Traveling on a road without resetting the service mode may
damage the transaxle.
(b) Special notes for speedometer test
NOTICE:
Rapid starting or quick acceleration/deceleration based on
the speedometer tester without load setting may damage
the transaxle.
(1) Depress the accelerator pedal slowly and gradually
accelerate at the time of measurement.
(2) After the measurement, use the brake to decelerate
gradually and stop.
(c) Special note for using the chassis dynamometer
Always set an appropriate load before starting the test.
NOTICE:
Rapid starting or quick acceleration/deceleration with in-
sufficient load may damage the transaxle.

B04757
B04752
HV Fuse
IGCT Relay Engine Room J/B
Engine Room R/B No. 2
B04760
IN±18
± INTRODUCTIONFOR ALL OF VEHICLES
18 Author: Date:
2001 PRIUS (RM778U)

Remove the service plug with the insulated
gloves on.
If the service plug cannot be removed due to damage to the rear
portion of the vehicle, remove the HV fuse or IGCT relay
instead.
(c) Moving the damaged vehicle
HINT:
If any of the following applies, tow the vehicle away using a tow
truck lorry.

One or more of the high±voltage components and cables
is damaged.

The driving, traction, or fuel system is damaged.

The READY light is not lit when you turn ignition key to the
ON position.
NOTICE:

Before towing the vehicle away using a break down
lorry, disconnect the cable from the negative (±) ter-
minal of the auxiliary battery and remove the service
plug.
Only if none of the above applies and you see no prob-
lems that might affect the driving operation, you are
allowed to drive the vehicle away from the place of ac-
cident.

Preform the procedure below if the READY light goes
off or you detect an abnormal noise, abnormal smell,
or strong vibration while traveling:
(1) Park the vehicle in a safe place.
(2) Move the shift lever to the P position and engage
the parking brake.
(3) Disconnect the cable from the negative (±) terminal
of the auxiliary battery.
(4) Remove the service plug with insulated gloves on.

IN±28
± INTRODUCTIONFOR ALL OF VEHICLES
28 Author: Date:
2001 PRIUS (RM778U)
8. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER
CAUTION:
If large amount of unburned gasoline flows into the converter, it may overheat and create a fire haz-
ard. To prevent this, observe the following precautions and explain them to your customer.
(a) Use only unleaded gasoline.
(b) Avoid prolonged idling.
Avoid running the engine at idle speed for more than 20 minutes.
(c) Avoid spark jump test.
(1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible.
(2) While testing, never race the engine.
(d) Avoid prolonged engine compression measurement.
Engine compression tests must be done as rapidly as possible.
(e) Do not run engine when fuel tank is nearly empty.
This may cause the engine to misfire and create an extra load on the converter.
(f) Avoid coasting with ignition turned off.
(g) Do not dispose of used catalyst along with parts contaminated with gasoline or oil.
9. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM
For vehicles with mobile communication systems such as two±way radios and cellular telephones, observe
the following precautions.
(1) Install the antenna as far as possible away from the ECU and sensors of the vehicle's electronic
system.
(2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the ve-
hicle's electronic systems. For details about ECU and sensors locations, refer to the section on
the applicable component.
(3) Avoid winding the antenna feeder together with other wiring as much as possible, and also avoid
running the antenna feeder parallel with other wire harnesses.
(4) Check that the antenna and feeder are correctly adjusted.
(5) Do not install powerful mobile communications system.
10. FOR USING OBD II SCAN TOOL OR TOYOTA HAND±HELD TESTER
CAUTION:
Observe the following items for safety reasons:

Before using the OBD II scan tool or TOYOTA hand±held tester, the OBD II scan tool's instruc-
tion book or TOYOTA hand±held tester's operator manual should be read thoroughly.

Be sure to route all cables securely when driving with the OBD II scan tool or TOYOTA hand±
held tester connected to the vehicle. (i.e. Keep cables away from feet, pedals, steering wheel
and shift lever.)

Two persons are required when test driving with the OBD II scan tool or TOYOTA hand±held
tester, one person to drive the vehicle and the other person to operate the OBD II scan tool or
TOYOTA hand±held tester.