water pump TOYOTA PRIUS 2001 Service User Guide

BODY ELECTRICAL ± AIR CONDITIONING 152
AIR CONDITIONING
DESCRIPTION
The air conditioning system in the Prius has the following features:
Both heating and demisting performances are realized by adopting performances are realized by adopting
the 2-way flow heater type air conditioning unit.
A multi-tank, super-slim structure evaporator has been adopted.
An automatic air conditioning system which provides enhanced air conditioning comfort according to the
occupant's senses has been adopted.
A semi-center location air conditioning unit, in which the evaporator and heater core are placed in the ve-
hicle's longitudinal direction, has been adopted.
A compact, high-performance scroll compressor with oil separator has been adopted.
The heat exchange efficiency has been improved through the adoption of the sub-cool condenser.
This condenser is integrated with the radiator to minimize the space they occupy in the engine compart-
ment.
A compact, lightweight, and highly efficient straight flow (full-path flow) aluminium heater core has been
adopted.
This heater core is integrated with a PTC (Positive Temperature Coefficient) heater, which excels in heat-
ing performance.
PTC heaters have been provided in the air duct at the footwell outlet in front of the air conditioning unit.
However, air conditioning without the PTC heaters is offered as an option on the U.S.A. models.
An electrical water pump with a bypass valve that provides a stable heater performance even if the engine
is stopped due to a function of the THS (TOYOTA Hybrid System) has been adopted.
A clean air filter that excels in removing pollen and dust is standard equipment.

BODY ELECTRICAL ± AIR CONDITIONING
165BE26165BE25
Discharge Port
Discharge Service Port
Pipe
Oil Discharge Hole
Shutter
Oil Storage Chamber
Discharge ValveRefrigerant and
Compressor OilRefrigerant
Compressor
Oil
182BE20182BE19
Flow of Coolant
Bypass Valve
Water Pump OFF
(Engine ON)Bypass Valve
Water Pump ON
(Engine OFF)Flow of Coolant163
2) Construction and Operation
The refrigerant gas that is discharged from the discharge port flows by rotating around the cylindrical
pipe in the oil separator. At this time, the centrifugal force that is created during the rotation separates
the refrigerant gas and the compressor oil due to the difference in their specific gravity. The refrigerant
gas with the lighter specific gravity passes through the inside of the pipe and travels from the discharge
service port to the outside of the compressor. The compressor oil with the heavier specific gravity is dis-
charged through the oil discharge hole in the shutter and is stored in the oil storage chamber. Then, the
compressor oil is fed again into the compressor and circulates inside the compressor.
4. Water Pump (For Air Conditioning)
An electrical water pump with a bypass valve that provides a stable heater performance even if the engine
is stopped due to a function of the THS has been adopted.
When the engine is running, this water pump ceases its operation and opens the bypass valve to minimize
the flow resistance of the coolant that is pumped by the engine water pump.

IN0CI±02
± INTRODUCTIONTERMS
IN±51
2001 PRIUS (RM778U)
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE±J1930 terms and abbreviations used in this manual in compliance with SAE rec-
ommendations, as well as their TOYOTA equivalents.
SAE
ABBREVIATIONSSAE TERMSTOYOTA TERMS
( )±±ABBREVIATIONS
A/CAir ConditioningAir Conditioner
ACLAir CleanerAir Cleaner, A/CL
AIRSecondary Air InjectionAir Injection (AI)
APAccelerator Pedal±
B+Battery Positive Voltage+B, Battery Voltage
BAROBarometric PressureHAC
CACCharge Air CoolerIntercooler
CARBCarburetorCarburetor
CFIContinuous Fuel Injection±
CKPCrankshaft PositionCrank Angle
CLClosed LoopClosed Loop
CMPCamshaft PositionCam Angle
CPPClutch Pedal Position±
CTOXContinuous Trap Oxidizer±
CTPClosed Throttle PositionLL ON, Idle ON
DFIDirect Fuel Injection (Diesel)Direct Injection (DI)
DIDistributor Ignition±
DLC1
DLC2
DLC3Data Link Connector 1
Data Link Connector 2
Data Link Connector 31: Check Connector
2: Total Diagnosis Comunication Link (TDCL)
3: OBD II Diagnostic Connector
DTCDiagnostic Trouble CodeDiagnostic Code
DTMDiagnostic Test Mode±
ECLEngine Control Level±
ECMEngine Control ModuleEngine ECU (Electronic Control Unit)
ECTEngine Coolant TemperatureCoolant Temperature, Water Temperature (THW)
EEPROMElectrically Erasable Programmable Read Only Memory
Electrically Erasable Programmable Read Only Memory
(EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFEEarly Fuel EvaporationCold Mixture Heater (CMH), Heat Control Valve (HCV)
EGRExhaust Gas RecirculationExhaust Gas Recirculation (EGR)
EIElectronic IgnitionTOYOTA Distributorless Ignition (TDI)
EMEngine ModificationEngine Modification (EM)
EPROMErasable Programmable Read Only MemoryProgrammable Read Only Memory (PROM)
EVAPEvaporative EmissionEvaporative Emission Control (EVAP)
FCFan Control±
FEEPROMFlash Electrically Erasable Programmable
Read Only Memory±
FEPROMFlash Erasable Programmable Read Only Memory±
FFFlexible Fuel±
FPFuel PumpFuel Pump
GENGeneratorAlternator
GNDGroundGround (GND)

SS177±02
± SERVICE SPECIFICATIONSCOOLING
SS±15
2001 PRIUS (RM778U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Drain plug12.71309
Water pump x Timing chain cover1111 08
Pump pulley x Water pump1515011
Water inlet x Cylinder block9.09080 in.´lbf
Electric cooling fan assembly x Radiator7.57666 in.´lbf
Fan motor x Fan shroud2.652723 in.´lbf
Fan x Fan motor6.46657 in.´lbf

SS1HI±01
± SERVICE SPECIFICATIONSHYBRID VEHICLE CONTROL
SS±21
2001 PRIUS (RM778U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Battery module x Battery carrier4.04035 in.´lbf
Battery clamp bolt x Battery carrier2323016
RH battery bracket x Battery carrier2323016
Battery ECU x Battery carrier3.33329 in.´lbf
Busber module x Battery module6.06153 in.´lbf
Power cable x SMR5.05044 in.´lbf
Service plug assembly x Battery carrier6.06153 in.´lbf
Battery cover x Battery carrier Bolt A
(See page HV±9) Bolt B
Bolt C
Screw18
8.0
7.0
6.0185
80
70
6113
71 in.´lbf
62 in.´lbf
53 in.´lbf
Battery bracket1818513
HV battery x Body1818513
Battery carrier catch bracket x Battery bracket8.08071 in.´lbf
Bracket x Converter & Inverter assembly2525518
Upper inverter cover x Converter & inverter assembly2.52522 in.´lbf
Inverter reservoir tank x Converter & inverter assembly8.08271 in.´lbf
Converter & inverter assembly x Body2121415
Ground cable x Radiator upper support8.08271 in.´lbf
Power cable for MG1 x Converter & inverter assembly7.07162 in.´lbf
Connector cover x Converter & inverter assembly2020415
Power cable for MG2 x Converter & inverter assembly Bolt A
(See page HV±22) Bolt B19.5
8.0199
8214
71 in.´lbf
Inverter terminal cover x Converter & inverter assembly8.08271 in.´lbf
HV water pump x Body7.07062 in.´lbf
Inverter radiator x Body8.08271 in.´lbf
Water temperature switch x Inverter radiator7.47565 in.´lbf
Blower assembly x Body5.05144 in.´lbf
Lower quarter ventilator duct x Body4.04135 in.´lbf
Inner ventilator duct x Body4.04135 in.´lbf
HV ECU x Body6.06053 in.´lbf

SS1HF±01
± SERVICE SPECIFICATIONSHYBRID TRANSAXLE
SS±25
2001 PRIUS (RM778U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Oil pump cover x MG2 assembly5.55649 in.´lbf
Transaxle oil drain plug4949836
Hybrid transaxle assembly x Engine3333224
Coolant drain plug x MG1 assembly3940029
Screw plug x MG1 assembly12.71309
Screw plug x MG2 assembly24.525018
Filler plug x MG2 assembly3940029
MG1 assembly x MG2 assembly2525018
Sleeve bracket x MG1 assembly131309
Lock clamp x MG1 assembly5.45548 in.´lbf
Oil strainer x MG2 assembly5.55649 in.´lbf
Oil pan x MG2 assembly7.67767 in.´lbf
Parking shaft cover x MG2 assembly1313010
Motor water jacket cover x MG2 assembly5.55649
Housing tube x MG1 assembly1515211
Detent spring set bolt101007
Parking cover x MG2 assembly5.55649 in.´lbf
Oil pump cover x plug7.357565 in.´lbf
Wiring harness connector x MG2 assembly5.55649 in.´lbf
Wiring harness connector x MG1 assembly5.55649 in.´lbf
Water jacket union5051037
High±voltage cable set bolt (3 under power cable cover)1818313
High±voltage cable set bolt (3 outside)5.55649 in.´lbf
Power cable cover x MG1 assembly4.84842 in.´lbf
Mounting bracket x MG2 assembly5253038
Shift lever assembly x Steering column88071 in.´lbf
Differential case x Ring gear879064

DI±198
± DIAGNOSTICSHYBRID VEHICLE CONTROL SYSTEM
2001 PRIUS (RM778U)P3107
(DI±242)
Airbag ECU Communication Cir-
cuit Malfunction
Wire Harness

Airbag Sensor Assembly
P3108
(DI±244)A/C Amplifier Communication
Circuit Malfunction
Wire Harness

A/C AmplifierX
P3109
(DI±245)Brake ECU Communication Cir-
cuit Malfunction
Wire Harness

Brake ECU
P3110
(DI±247)IGCT Relay Malfunction
Wire Harness

IGCT Relay
P3115
(DI±249)System Main Relay Malfunction

Wire Harness

System Main Relay

HV ECU

P3120
(DI±252)HV Transaxle Malfunction

HV Transaxle

Wire Harness

System Main Relay

P3125
(DI±266)Converter & Inverter Assembly
Malfunction
Converter & Inverter Assembly

Wire Harness
P3130
(DI±302)Inverter Cooling System Mal-
function

Inverter Water Pump

Wire Harness

IG2 Relay

Electric Cooling Fan System

P3135
(DI±305)Circuit Breaker Sensor Malfunc-
tion
Circuit Breaker Sensor

Wire Harness
P3140
(DI±307)Interlock Malfunction

Interlock Switch

Inverter Terminal Cover

Converter & Inverter Assembly

Wire Harness

P3145
(DI±310)Vehicle Speed Sensor Circuit
Malfunction
Wire HarnessX
*: : Hybrid system warning light lights up. X: Hybrid system warning light does not light up.

± DIAGNOSTICSHYBRID VEHICLE CONTROL SYSTEM
DI±205
2001 PRIUS (RM778U)DTC NO.
INF. CodeDetection ItemDetecting Condition
326Generator inverter current sensor malfunction (V phase sub sensor)
327Open in generator inverter current sensor (V phase sub sensor)
328Generator inverter current sensor malfunction (V phase main sensor)
329(when there is a history that the state of malfunction continued during in-
verter fail safe mode)
330Open in generator inverter current sensor (V phase main sensor)
331(when there is a history that the state of malfunction continued during in-
verter fail safe mode)
332Generator inverter current sensor V phase performance problem
333Generator Inverter Current
(when there is a history that the state of malfunction continued during in-
verter fail safe mode)
334
Generator Inverter Current
Sensor MalfunctionGenerator inverter current sensor malfunction (W phase sub sensor)
335Open in generator inverter current sensor (W phase sub sensor)
P3125336Generator inverter current sensor malfunction (W phase main sensor)P3125
337(when there is a history that the state of malfunction continued during in-
verter fail safe mode)
338Open in generator inverter current sensor (W phase main sensor)
339(when there is a history that the state of malfunction continued during in-
verter fail safe mode)
340Generator inverter current sensor W phase performance problem
341(when there is a history that the state of malfunction continued during in-
verter fail safe mode)
342Motor Gate Shutdown Signal+B short in generator gate shutdown signal circuit
343
Motor Gate Shutdown Signal
Line ConnectionOpen or GND short in generator gate shutdown signal circuit
344Failure in Monitoring Genera-
tor Torque PerformanceFailure in monitoring generator torque performance
345Abnormal Current Value of
GeneratorAbnormal current value of generator
P3130346Inverter Cooling System Mal-Water pump system malfunctionP3130347
Inverter Cooling System Mal
functionElectric cooling fan system malfunction
P3135348Circuit Breaker Sensor Mal-GND short in circuit breaker sensorP3135349
Circuit Breaker Sensor Mal
functionOpen or +B short in circuit breaker sensor
P3140350It l kMlf tiSafety devices operating with vehicle is stopped (ILK signal ON)P3140351Interlock MalfunctionOpen circuit in interlock signal circuit while vehicle is running
P3145352Vehicle Speed Sensor Circuit
MalfunctionNo input of vehicle speed signal during cruise control driving

A14736
BatteryMAINB±G 1
1
F18 1 1
5
1
F132 3 2
2Engine Room J/B
W±B IK1 2
14
5
AM2 B±WB±W
B±W I15
Ignition SW W±R
6 711
IG2 AM2
Instrument Panel J/B
2C
1K 1A 2G9
1J
1B
B
F12IG2 Relay
Fusible Link
Block No. 1
Fusible Link
Block No. 2 1J
2G
2BW±R
13 3
IE AA AB±W
2
W±B W±B
W±BW3
Water
Pump
Motor
J1
J/C J7
J/C W±B DI±302
± DIAGNOSTICSHYBRID VEHICLE CONTROL SYSTEM
2001 PRIUS (RM778U)
DTC P3130 Inverter Cooling System Malfunction
CIRCUIT DESCRIPTION
The HV ECU checks the operation of the inverter water pump and detects malfunction.
HINT:

When using an OBD scan tool other than TOYOTA hand±held tester, check all the steps.

When using TOYOTA hand±held tester, confirm the information code and check it.
DTC P3130 ± Information code 346
INF. code.Detecting ConditionTrouble Area
346Water pump system malfunction

Inverter water pump

IG2 relay

Wire harness
WIRING DIAGRAM
DI839±02

± DIAGNOSTICSHYBRID VEHICLE CONTROL SYSTEM
DI±303
2001 PRIUS (RM778U)
INSPECTION PROCEDURE
1Check wire harness (See page IN±41).
HINT:
After removing the IG2 relay, check the electrical condition of each terminal.

No. 1 terminal: With the IG switch ON, 10 ± 14 V

No. 2 terminal : Continuity between the IG2 relay No. 2 terminal and body ground (less than 1 W )

No. 3 terminal: Continuity between the IG2 relay No. 3 terminal and water pump No. 2 terminal (less
than 1 W )

No. 5 terminal: Always 10 ± 14 V
Continuity between the water pump No. 1 terminal and body ground (less than 1 W )
NG Repair or replace wire harness.
OK