TOYOTA PRIUS 2001 Service Repair Manual

H15464
SST
SST
R13455
10 m (33 ft) or more
± BODYSEAT BELT PRETENSIONER
BO±95
2001 PRIUS (RM778U)
(2) Connect the 2 SST, then connect them to the seat
belt pretensioner.
SST
Driver's side: 09082±00700, 09082±00730
Except driver's side: 09082±00700, 09082±00740
NOTICE:
To avoid damaging the SST connector and wire harness.
(3) Move the SST to at least 10 m (33 ft) away from the
front of the vehicle.
(4) Close all the doors and windows of the vehicle.
NOTICE:
Take care not to damage the SST wire harness.
(5) Connect the SST red clip to the battery positive (+)
terminal and the black clip to the negative (±) termi-
nal.
(d) Activate the seat belt pretensioner.
(1) Confirm that no one is inside the vehicle or within 10
m (33 ft) area around the vehicle.
(2) Press the SST activation switch and activate the
seat belt pretensioner.
HINT:
The seat belt pretensioner operates simultaneously as the LED
of the SST activation switch lights up.
(e) Dispose of the front seat outer belt (with seat belt preten-
sioner).
CAUTION:

The front seat outer belt is very hot when the seat belt
pretensioner is activated, so leave it alone for at least
30 minutes after activation.

Use gloves and safety glasses when handling a front
seat outer belt with the activated seat belt pretension-
er.

Always wash your hands with water after completing
the operation.

Do not apply water, etc. to a front seat outer belt with
the activated seat belt pretensioner.
HINT:
When scrapping a vehicle, activate the seat belt pretensioner
and scrap the vehicle with the activated front seat outer belt still
installed.
2. ACTIVATION WHEN DISPOSING OF FRONT SEAT
OUTER BELT ONLY
NOTICE:

When disposing of the front seat outer belt (with seat
belt pretensioner) only, never use the customer's ve-
hicle to activate the seat belt pretensioner.

AB0158
SSTBattery
H15464
SST
SST
H15465
BO±96
± BODYSEAT BELT PRETENSIONER
2001 PRIUS (RM778U)

Be sure to follow the procedure given on the next
page when activating the seat belt pretensioner.
HINT:
Have a battery ready as the power source when activating the
seat belt pretensioner.
(a) Remove the front seat outer belt (See page BO±90).
HINT:
Cut the belt near the seat belt retractor.
(b) Check the functioning of SST.
(See step 1±(a))
SST
Driver's side: 09082±00700, 09082±00730
Except driver's side: 09082±00700, 09082±00740
(c) Install the SST.
(1) Connect the 2 SST, then connect them to the seat
belt pretensioner.
SST
Driver's side: 09082±00700, 09082±00730
Except driver's side: 09082±00700, 09082±00740
NOTICE:
To avoid damaging the SST connector and wire harness.
(2) Place the front seat outer belt on the ground and
cover it with the disc wheel with tire.
NOTICE:
Place the front seat outer belt as shown in the illustration.
Also, secure some slack for the SST wire harness inside
the tire.
(3) Move the SST at least 10 m (33 ft) away from the
disc wheel.
NOTICE:
Take care not to damage the SST wire harness.
(d) Activate the seat belt pretensioner.
(1) Connect the SST red clip to the battery positive (+)
terminal and black clip to the battery negative (±)
terminal.
(2) Check that no one is within 10 m (33 ft) area around
the disc wheel.
(3) Press the SST activation switch and activate the
seat belt pretensioner.

R05181
10 m (33 ft) or more
H15466
± BODYSEAT BELT PRETENSIONER
BO±97
2001 PRIUS (RM778U)
HINT:
The seat belt pretensioner operates simultaneously as the LED
of the SST activation switch lights up.
(e) Dispose of the front seat outer belt (with seat belt preten-
sioner).
CAUTION:

The front seat outer belt is very hot when the seat belt
pretensioner is activated, so leave it alone for at least
30 minutes after activation.

Use gloves and safety glasses when handling a front
seat outer belt with the activated seat belt pretension-
er.

Always wash your hands with water after completing
the operation.

Do not apply water, etc. to a front seat outer belt with
the activated seat belt pretensioner.
(1) Remove the disc wheel and SST.
(2) Place the front seat outer belt in a vinyl bag, tie the
end tightly and dispose of it in the same way as oth-
er general parts dispose.

BO3TA±01
H15467H15360H16310
Driver's side:
Except driver's side:
H15375
± BODYSEAT BELT PRETENSIONER
BO±99
2001 PRIUS (RM778U)
INSTALLATION
NOTICE:

Never use seat belt pretensioner from another ve-
hicle. When replacing parts, replace them with new
parts.

Make sure that the front seat outer belt is installed
with the specified torque.

If the front seat outer belt has been dropped, or there
are cracks, dents or other defects in the case or con-
nector, replace the front seat outer belt with a new
one.

When installing the front seat outer belt, take care that
the wiring does not interfere with other parts and is
not pinched between other parts.
1. INSTALL FRONT SEAT OUTER BELT
(a) Install the retractor of front seat outer belt.
(1) Install the retractor of front seat outer belt with the
bolt.
Torque: 4.9 N´m (50 kgf´cm, 43 in.´lbf)
(2) Connect the pretensioner connector as shown in
the illustration.
(3) Connect the tension reducer connector.
NOTICE:
When handling the pretensioner connector and tensionre-
ducer, take care not to damage the wire harness.
(b) Install the floor anchor with the bolt.
Torque: 42 N´m (430 kgf´cm, 31 ft´lbf)
(c) Install the floor anchor cover.
(d) Install the shoulder anchor with the bolt.
Torque: 42 N´m (430 kgf´cm, 31 ft´lbf)
(e) Install the shoulder anchor cover.

H13691
2 Clips
H13690
H13689
BO±100
± BODYSEAT BELT PRETENSIONER
2001 PRIUS (RM778U)
2. INSTALL CENTER PILLAR LOWER GARNISH
Install the center pillar lower garnish to the body.
3. INSTALL FRONT DOOR OPENING TRIM
4. INSTALL REAR DOOR OPENING TRIM
5. INSTALL REAR DOOR INSIDE SCUFF PLATE
Install the rear door inside scuff plate to the body.
6. INSTALL FRONT DOOR INSIDE SCUFF PLATE
Install the front door inside scuff plate to the body.

AC2810
AC0Y9±05
AC2811
N11084
Wrong Okay
HI LO HILO
± AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC±1
1889 Author: Date:
2001 PRIUS (RM778U)
AIR CONDITIONING SYSTEM
PRECAUTION
1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED
AREA OR WEAR A NAKED FLAME
2. ALWAYS WEAR EYE PROTECTION
3. BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN
YOUR EYES OR ON YOUR SKIN
If liquid refrigerant gets in your eyes or on your skin.
(a) Wash the area with lots of cool water.
CAUTION:
Do not rub your eyes or skin.
(b) Apply clean petroleum jelly to the skin.
(c) Go immediately to a physician or hospital for professional
treatment.
4. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED
FLAME
5. BE CAREFUL NOT TO DROP CONTAINER AND NOT
TO APPLY PHYSICAL SHOCKS TO IT
6. DO NOT OPERATE COMPRESSOR WITHOUT
ENOUGH REFRIGERANT IN REFRIGERATION SYS-
TEM
If there is not enough refrigerant in the refrigerant system oil lu-
brication will be insufficient and compressor burnout may occur,
so that care to avoid this, necessary care should be taken.
7. DO NOT OPEN PRESSURE MANIFOLD VALVE WHILE
COMPRESSOR IS OPERATE
If the high pressure valve is opened, refrigerant flows in the re-
verse direction and could cause the charging cylinder to rup-
ture, so open and close the only low pressure valve.
8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH
REFRIGERANT
If refrigerant is overcharged, it causes problems such as insuffi-
cient cooling, poor fuel economy, engine overheating etc.

AC±2
± AIR CONDITIONINGAIR CONDITIONING SYSTEM
1890 Author: Date:
2001 PRIUS (RM778U)
9. SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
The PRIUS is equipped with an SRS (Supplemental Restraint
System) such as the driver, front passenger 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 ( includ-
ing removal or installation of parts, inspection or replacement),
be sure to read the precautionary notices in the RS section.

AC0YB±04
I17971
ight Glass
± AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC±3
2001 PRIUS (RM778U)
ON±VEHICLE INSPECTION
1. INSPECT REFRIGERANT VOLUME
Observe the sight glass on the liquid tube.
Test conditions:
MAX. switch ON
Blower speed control set at ºHIº
Temperature control set at ºMAX. COOLº
Running engine at 1,500 rpm
Fully open the doors
ItemSymptomAmount of refrigerantRemedy
1Bubbles present in sight glassInsufficient*
(1) Check for gas leakage with gas leak de-
tector and repair if necessary
(2) Add refrigerant until bubbles disappear
2No bubbles present in sight glassNone, sufficient or too muchRefer item 3 and 4
3No temperature difference between com-
pressor inlet and outletEmpty or nearly empty
(1) Check for gas leakage with gas leak de-
tector and repair if necessary
(2) Add refrigerant until bubbles disappear
4Temperature between compressor inlet and
outlet is noticeably differentCorrect or too muchRefer to items 5 and 6
5Immediately after air conditioning is turned
off, refrigerant in sight glass stays clearToo much
(1) Discharge refrigerant
(2) Evacuate air and charge proper amount
of purified refrigerant
6When air conditioning is turned off, refriger-
ant foams and then stays clearCorrect±
*: Bubbles in the sight glass with ambient temperatures higher than usual can be considered normal if cooling
is sufficient.

I01386
AC±4
± AIR CONDITIONINGAIR CONDITIONING SYSTEM
2001 PRIUS (RM778U)
2. INSPECT REFRIGERANT PRESSURE WITH MAN-
IFOLD GAUGE SET
This is a method in which the trouble is located by using a man-
ifold gauge set. Read the manifold gauge pressure when the
these conditions are established.
Test conditions:
Temperature at the air inlet with the switch set
at RECIRC is 30 ± 35 °C (86 ± 95 °F)
Engine running at 1500 rpm
Blower speed control switch at ºHIº position
Temperature control dial on ºCOOLº position
HINT:
It should be noted that the gauge indications may vary slightly
due to ambient temperature conditions.
(1) Normally functioning refrigeration system.
Gauge reading:
Low pressure side:
0.15 ± 0.25 MPa (1.5 ± 2.5 kgf/cm
2)
High pressure side:
1.37 ± 1.57 MPa (14 ± 16 kgf/cm
2)

I01387
Condition : Periodically cools and then fails to cool
I01388
Condition: Insufficient cooling
± AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC±5
2001 PRIUS (RM778U)
(2) Moisture present in refrigeration system.
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
During operation, pressure on low
pressure side sometimes become
a vacuum and sometime normal
Moisture entered in refrigeration
system freezes at expansion valve
orifice and temporarily stops cycle,
by normal state is restored after a
time when the ice melts Drier oversaturated state
 Moisture in refrigeration system
freezes at expansion valve orifice
and blocks circulation of refriger-
ant(1) Replace condenser
(2) Remove moisture in cycle
through repeatedly evacuating air
(3) Charge proper amount of new
refrigerant
(3) Insufficient cooling
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
 Pressure low on both low and
high pressure sides
 Bubbles seen in sight glass con-
tinuously
 Insufficient cooling performance
Gas leakage at some place in re-
frigeration systemInsufficient refrigerant in sys-
tem
 Refrigerant leaking
(1) Check for gas leakage with gas
leak detector and repair if neces-
sary
(2) Charge proper amount of re-
frigerant
(3) If indicated pressure value is
near 0 when connected to gauge,
create the vacuum after inspecting
and repairing the location of the
leak