TOYOTA PRIUS 2001 Service Repair Manual

I06919
Disconnect the tube
using hand
Screw
Driver
Tube
I17982
I18108
View
Upper
Lower RH LH
MarkingHose Clip
A
View
Second RidgeA
Upper
Lower
20°
20°
I17984
I17985
AC±26
± AIR CONDITIONINGAIR CONDITIONING UNIT
2001 PRIUS (RM778U)
NOTICE:

Do not use tools like screwdriver to remove the tube.

Cap the open fittings immediately to keep moisture or
dirt out of the system.
HINT:
At the time of reassembly, please refer to the following item.
Lubricate 4 new O±rings with compressor oil and install them
to the valve.
5. DISCONNECT WATER HOSES FROM HEATER RA-
DIATOR PIPES
(a) Using pliers, grip the claw of the hose clip and slide the
hose clip along the hose.
(b) Disconnect the heater hoses.
HINT:
At the time of installation, please refer to the following item.
Push the water hose onto the heater radiator pipe as far as se-
cond ridge on the pipe and install the hose clip.
6. REMOVE INSTRUMENT PANEL AND REINFORCE-
MENT (See page BO±62)
7. REMOVE BLOWER UNIT (See page AC±32)
8. REMOVE A/C UNIT
(a) Remove the 2 screws and defroster duct.
(b) Remove the foot air duct.
(c) Disconnect the connectors.
(d) Remove the 2 nuts and A/C unit.

AC35U±01
I11223
SST
I18010
SST
I18012
N20013
R±Shape
RotorSnap Ring
Compressor
I18011
AC±40
± AIR CONDITIONINGCOMPRESSOR AND MAGNETIC CLUTCH
2001 PRIUS (RM778U)
DISASSEMBLY
1. REMOVE PRESSURE PLATE
(a) Using SST and a socket wrench, remove the shaft bolt.
SST 07112±76050
Torque: 13.2 N´m (135 kgf´cm, 9 ft´lbf)
(b) Install SST to the pressure plate.
SST 07112±66040
(c) Using SST and a socket wrench, remove the pressure
plate.
SST 07112±76050, 07112±66040
(d) Remove the shims from the shaft.
2. REMOVE ROTOR
(a) Remove the snap ring.
NOTICE:
At the time of reassembly, please refer to the following
item.
The snap ring should be installed so that its beveled side
faces up.
(b) Using a plastic hammer, tap the rotor off the shaft.
NOTICE:
Be careful not to damage the pulley when tapping on the ro-
tor.

I18013
I18014
N20012
R±Shape
Snap Ring
Startor
Compressor
N18359
± AIR CONDITIONINGCOMPRESSOR AND MAGNETIC CLUTCH
AC±41
2001 PRIUS (RM778U)
3. REMOVE STATOR
(a) Disconnect the connector from the stator.
(b) Remove the screw and stator lead wire.
(c) Remove the snap ring.
NOTICE:
At the time of reassembly, please refer to the following
item.
The snap ring should be installed so that its beveled side
faces up.
(d) Remove the stator.

AC36Q±01
I17953
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable partBracket Water Hose
Radiator
Upper
Support

O±RingRadiator
Reservoir
Hose Suction Hose
Radiator and
Condenser
Module
Discharge Hose
Liquid Tube Discharge
Tube
5.4 (55, 48 in.´lbf)
22 (225, 16)
5.4 (55, 48 in.´lbf)

O±Ring
10 (100, 7)

O±Ring

O±RingSuction Tube

O±Ring
Bracket
Radiator
Upper
Support
Radiator
Hose
Condenser FanConnector
RH Engine Under Cover
LH Engine Under Cover
Front Bumper
O±Ring
32 (330, 24)
Front Spoiler Cover
± AIR CONDITIONINGRADIATOR AND CONDENSER MODULE
AC±45
2001 PRIUS (RM778U)
COMPONENTS

I18287
Radiator & Condenser Module
Bracket Drier
Filter
O±Ring
Cap
12.3 (125, 9)
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part

Compressor oil ND±OIL 8 or equivalent
AC±46
± AIR CONDITIONINGRADIATOR AND CONDENSER MODULE
2001 PRIUS (RM778U)

AC36R±01
I17955
I17954
± AIR CONDITIONINGRADIATOR AND CONDENSER MODULE
AC±47
2001 PRIUS (RM778U)
REMOVAL
1. DISCHARGE REFRIGERANT FROM REFRIGERATION
SYSTEM
HINT:
At the time of installation, please refer to the following item.
Evacuate air from refrigeration system.
Charge system with refrigerant and inspect for leakage of refrig-
erant.
Specified amount: 500 ± 50 g (17.64 ± 1.76 oz.)
2. DRAIN ENGINE COOLANT FROM RADIATOR
HINT:
It is not necessary to drain out all the coolant.
3. REMOVE CONDENSER FAN ASSEMBLY
(See Page AC±69)
4. REMOVE FRONT BUMPER (See Page BO±4)
5. REMOVE RADIATOR RESERVOIR HOSE
6. DISCONNECT DISCHARGE AND LIQUID TUBE
(a) Remove the 2 bolts and disconnect discharge and liquid
tube.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
NOTICE:
Cap open the fittings immediately to keep moisture or dirt
out of the system.
HINT:
At the time of installation, please refer to the following item.
Lubricate 2 new O±rings with compressor oil and install them
to the tubes.
(b) Remove the bolt.
(c) Disconnect the liquid tube and remove the bracket.
7. REMOVE RADIATOR UPPER SUPPORT
Remove the 2 bolts and 2 radiator upper supports.

I17968
AC±48
± AIR CONDITIONINGRADIATOR AND CONDENSER MODULE
2001 PRIUS (RM778U)
8. REMOVE RADIATOR & CONDENSER MODULE
(a) Push the radiator & condenser module toward engine.
(b) Pull up the radiator until the lower radiator support is re-
moved.
(c) Pull it downward to remove it.

I18027
Heater Main Relay
Magnetic
Clutch
Relay
Cooling
Fan No. 3
Relay
Cooling
Fan No. 1
Relay
Cooling
Fan No. 2
Relay
AC36O±01
I18028Heater 2 Relay
Heater 1 Relay
Heater 3 Relay
Water
Pump
Relay
I18286
3
2
15 4
1 4
32
5
N23635
3
2
15
4
Z18060
13
2 5
5 2
3
1
± AIR CONDITIONINGRELAY
AC±65
1953 Author: Date:
2001 PRIUS (RM778U)
RELAY
INSPECTION
1. REMOVE RELAY
(a) Remove the relay from the engine room J/B.
(b) Remove the relay from the engine room R/B No. 3.
2. INSPECT HEATER MAIN RELAY CONTINUITY
ConditionTester connectionSpecified condition
Constant3 ± 5
2 ± 4Continuity
Apply B+ between
terminals 5 and 3.1 ± 2Continuity
If continuity is not as specified, replace the relay.
3. INSPECT COOLING FAN NO. 2 RELAY CONTINUITY
ConditionTester connectionSpecified condition
Constant1 ± 2
3 ± 4Continuity
Apply B+ between
terminals 1 and 2.3 ± 5Continuity
If continuity is not as specified, replace the relay.
4. INSPECT MAGNETIC CLUTCH, COOLING FAN NO. 1,
3, HEATER 1, 2, WATER PUMP RELAY CONTINUITY
ConditionTester connectionSpecified condition
Constant1 ± 2Continuity
Apply B+ between
terminals 1 and 2.3 ± 5Continuity
If continuity is not as specified, replace the relay.

I07286
1
2 3
51
2
3
5 AC±66
± AIR CONDITIONINGRELAY
1954 Author: Date:
2001 PRIUS (RM778U)
5. INSPECT HEATER 3 RELAY CONTINUITY
ConditionTester connectionSpecified condition
Constant1 ± 2Continuity
Apply B+ between
terminals 1 and 2.3 ± 5Continuity
If continuity is not as specified, replace the relay.

AC36D±01
I17963
I17964
± AIR CONDITIONINGCONDENSER FAN
AC±69
2001 PRIUS (RM778U)
REMOVAL
1. DISCHARGE REFRIGERANT FROM REFRIGERATION
SYSTEM
HINT:
At the time of installation, please refer to the following item.
Evacuate air from refrigeration system.
Charge system with refrigerant and inspect for leakage of refrig-
erant.
Specified amount: 500 ± 50 g (17.64 ± 1.76 oz.)
2. DRAIN ENGINE COOLANT FROM RADIATOR
HINT:
It is not necessary to drain out all coolant.
3. REMOVE BRACKETS
(a) Remove the water hose from fan shroud.
(b) Remove the 5 bolts and 2 brackets.
4. REMOVE SUCTION AND DISCHARGE HOSES
(a) Remove the 2 bolts and disconnect the both hoses.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
HINT:
At the time of installation, please refer to the following item.
Lubricate 2 new O±rings with compressor oil and install them
to the tubes.
(b) Loosen the 2 nuts and remove the both hoses.
Torque:
Suction hose 32 N´m (330 kgf´cm, 24 ft´lbf)
Discharge hose 22 N´m (225 kgf´cm, 16 ft´lbf)
HINT:
At the time of installation, please refer to the following item.
Lubricate 2 new O±rings with compressor oil and install them
to the tubes.