light TOYOTA PRIUS 2001 Service Repair Manual

BO3QS±01
H15480
H15418
H15419
H15420
BO±26
± BODYLUGGAGE COMPARTMENT DOOR AND HINGE
2001 PRIUS (RM778U)
REMOVAL
1. REMOVE LUGGAGE COMPARTMENT DOOR TRIM
Remove the 10 clips and luggage compartment door trim.
2. REMOVE LUGGAGE COMPARTMENT DOOR LOCK
(a) Remove the 2 bolts and luggage compartment door lock.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
(b) Disconnect the link and cable from the lock.
3. REMOVE LUGGAGE COMPARTMENT DOOR OUTER
GARNISH
(a) Remove the 4 nuts.
(b) Remove the luggage compartment door outer garnish
and key cylinder.
4. REMOVE LICENCE PLATE LIGHT
(a) Disconnect the connector.
(b) Remove the licence plate light as shown in the illustration.
(c) Employ the same manner described above to the other
side.
(d) Using a clip remover, remove the clamps.
5. REMOVE LUGGAGE COMPARTMENT DOOR
Remove the 4 bolts luggage compartment door.
Torque: 8.3 N´m (85 kgf´cm, 74 in.´lbf)
6. REMOVE LUGGAGE REAR FLOOR FINISH PLATE
(a) Using a clip remover, remove the 4 clips.
(b) Remove the rear floor finish plate.
7. REMOVE LUGGAGE COMPARTMENT DOOR WEATH-
ERSTRIP

BO3PW±01
H13671
Primer M
Primer M
B
A
± BODYROOF DRIP SIDE FINISH MOULDING
BO±39
2001 PRIUS (RM778U)
INSTALLATION
1. CLEAN CONTRACT SURFACE OF BODY
(a) Using a heat light, heat the moulding surface to 40 ± 60
°C (104 ± 140 °F).
NOTICE:
Do not heat the body excessively.
(b) Using a knife, cut away any rough areas on the body.
NOTICE:
Be careful not to damage the body.
(c) Wipe off stains with cleaner.
2. CLEAN MOULDING
If reusing the moulding.
(a) Using a heat light, heat the moulding surface to 20 ± 30
°C (68 ± 86 °F).
NOTICE:
Do not heat the moulding excessively.
(b) Using a knife, cut the remaining adhesive from the mould-
ing.
NOTICE:
Be careful not to damage the moulding.
(c) Wipe off stains with cleaner.
3. COAT CONTACT SURFACE OF BODY WITH PRIMER
ºMº
Using a brush, coat the contact surface on the body with Primer
M as shown in the illustration.
Front end:
A: 24.9 mm (0.980 in.)
B: 47.5 mm (1.870 in.)
Rear end:
A: 23.2 mm (0.913 in.)
B: 57.5 mm (2.264 in.)
NOTICE:

Let the primer coating dry for 3 minutes or more.

Do not coat the adhesive.

Do not keep any of the opened Primer M for later use.

H00464
Adhesive
Dam
B
A
BO2821Reference Marks
H00679
Windshield Glass
Adhesive
± BODYWINDSHIELD
BO±49
2001 PRIUS (RM778U)
HINT:
After cutting off the tip, use all adhesive within the time de-
scribed in the table below.
TemperatureTackfree time
35 °C (95 °F)15 minutes
20 °C (68 °F)100 minutes
5 °C (41 °F)8 hours
(b) Load the cartridge into the sealer gun.
(c) Coat the glass with adhesive as shown.
A: 12 mm (0.47 in.)
B: 8 mm (0.31 in.)
10. INSTALL WINDSHIELD GLASS AND MOULDING
(a) Install the glass, aligning the reference marks using a suc-
tion rubber.
HINT:
Check to see that the stoppers are attached to the body correct-
ly.
(b) Lightly press the glass front surface for close contact.
(c) Correct insufficient or protruded adhesive agent using a
spatula.
HINT:
Apply the adhesive agent up to the windshield glass edge.

BO3Q1±01
H13694
5 Clips
H15383
H15384
4 Clips
± BODYBACK WINDOW GLASS
BO±53
2001 PRIUS (RM778U)
REMOVAL
1. REMOVE REAR SEAT CUSHION (See page BO±83)
2. REMOVE REAR SEATBACK (See page BO±83)
3. REMOVE UPPER PART OF REAR DOOR OPENING
TRIMS
4. REMOVE ROOF SIDE INNER GARNISH
(a) Using a screwdriver, disengage the clips.
HINT:
Tape the screwdriver tip before use.
(b) Pull the garnish upward to remove it.
(c) Employ the same manner described above to the other
side.
5. REMOVE HIGH±MOUNTED STOP LIGHT
(a) Remove the clip, then pull the high±mounted stop light
cover.
(b) Disconnect the connector.
(c) Remove the 2 screws and high±mounted stop light.
6. REMOVE CRS TETHER ANCHORS
Remove the 3 CRS tether anchor covers and 3 CRS tether an-
chor brackets.
7. REMOVE PACKAGE TRAY TRIM PANEL
(a) Pull the package tray trim panel upward to disengage the
clips.
(b) Remove the rear seat outer belts through the cutout on
the package tray trim.
(c) Pull the package tray trim panel forward to remove it.
8. REMOVE SILENCER PAD
9. REMOVE REAR ASSIST GRIPS
(a) Using a screwdriver, remove the caps.
HINT:
Tape the screwdriver tip before use.
(b) Remove the 4 screws and 2 rear assist grips.
10. PULL DOWN REAR PART OF ROOF HEADLINING
Remove the 2 clips.

H15384
4 Clips
H15383
H13694
5 Clips BO±58
± BODYBACK WINDOW GLASS
2001 PRIUS (RM778U)
12. INSTALL REAR PART OF ROOF HEADLINING
Install the 2 clips.
13. INSTALL REAR ASSIST GRIPS
(a) Install the 2 rear assist grips with the 4 screws.
(b) Install the caps.
14. INSTALL SILENCER PAD
15. INSTALL PACKAGE TRAY TRIM PANEL
(a) Install the seat belt through the cutout of the package tray
trim.
(b) Install the package tray trim as shown in the illustration.
16. INSTALL CRS TETHER ANCHORS
(a) Install the 3 CRS tether anchor brackets.
Torque: 20 N´m (200 kgf´cm, 14 ft´lbf)
(b) Install the CRS tether anchor covers.
17. INSTALL HIGH±MOUNTED STOP LIGHT
(a) Install the high±mounted stop light with the 2 screws.
(b) Connect the connector.
(c) Install the high±mounted stop light cover, then install the
clip.
18. INSTALL ROOF SIDE INNER GARNISH
(a) Install the roof side inner garnish as shown in the illustra-
tion.
(b) Employ the same manner described above to the other
side.
19. INSTALL UPPER PART OF REAR DOOR OPENING
TRIMS
20. INSTALL REAR SEATBACK (See page BO±86)
21. INSTALL REAR SEAT CUSHION (See page BO±86)

H13692
H13693
Clip
H13694
5 Clips
H13603
2 Clips
H15355
± BODYROOF HEADLINING
BO±71
2001 PRIUS (RM778U)
9. REMOVE FRONT SEAT OUTER BELT SHOULDER AN-
CHOR
(a) Using a screwdriver, remove the anchor cover cap.
HINT:
Tape the screwdriver tip before use.
(b) Remove the bolt and front seat outer belt shoulder an-
chor.
Torque: 42 N´m (430 kgf´cm, 31 ft´lbf)
(c) Employ the same manner described above to the other
side.
10. REMOVE CENTER PILLAR GARNISH
(a) Using a screwdriver, remove the center pillar garnish.
HINT:
Tape the screwdriver tip before use.
(b) Employ the same manner described above to the other
side.
11. REMOVE ROOF SIDE INNER GARNISH
(a) Using a screwdriver, remove the roof side inner garnish.
HINT:
Tape the screwdriver tip before use.
(b) Employ the same manner described above to the other
side.
12. REMOVE FRONT PILLAR GARNISH AND NO. 1
FRONT PILLAR SPACERS
(a) Using a screwdriver, remove the front pillar garnish.
HINT:
Tape the screwdriver tip before use.
(b) Remove the 4 screws and 2 No. 1 front pillar spacers.
(c) Employ the same manner described above to the other
side.
13. REMOVE ROOM LIGHT ASSEMBLY
(a) Using a screwdriver, remove the lens.
HINT:
Tape the screwdriver tip before use.
(b) Remove the 2 screws and room light assembly.
(c) Disconnect the connector.

H15356
H15357
H15383
H15358P
H15359P BO±72
± BODYROOF HEADLINING
2001 PRIUS (RM778U)
14. REMOVE INNER REAR VIEW MIRROR
(a) Using a moulding remover, remove the cover as shown in
the illustration.
(b) Remove the 2 screws and inner rear view mirror.
Torque: 2.9 N´m (30 kgf´cm, 26 in.´lbf)
15. REMOVE MAP LAMP
(a) Using a screwdriver, remove the map lamp.
(b) Disconnect the map lamp connector.
16. REMOVE ASSIST GRIPS
(a) Using a screwdriver, remove the caps.
HINT:
Tape the screwdriver tip before use.
(b) Remove the 6 bolts and 3 assist grips.
17. REMOVE HIGH±MOUNTED STOP LIGHT
(a) Remove the clip then pull the high±mounted stoplight
cover.
(b) Disconnect the connector.
(c) Remove the 2 screws and high±mounted stop light.
18. REMOVE SUN VISORS
(a) Remove the 4 screws and pull the sun visors downward.
(b) Disconnect the connectors.
19. REMOVE SUN VISOR HOLDERS
Remove the 2 screws and 2 holders.
20. REMOVE ROOF HEADLINING
(a) Remove the 2 clips.
(b) Pull the roof headlining downward to remove it.
21. REMOVE FRONT AND REAR SIDE RAIL SPACER
(a) Remove the 4 screws and front side rail spacer.
(b) Remove the 4 screws and rear side rail spacer.
(c) Employ the same manner described above to the other
side.

BO3T5±01
BO0632
BO0633
45° 15° BO±88
± BODYSEAT BELT
2001 PRIUS (RM778U)
INSPECTION
CAUTION:
Replace the seat belt assembly (outer belt, inner belt, bolts,
nuts or sill±bar) if it has been used in a severe impact. The
entire assembly should be replaced even if damage is not
obvious.
1. RUNNING TEST (IN SAFE AREA)
(a) Fasten the front seat belts.
(b) Drive the car at 10 mph (16 km/h) and slam on the brakes.
Check that the belt locks and cannot be extended at this
time.
HINT:
Conduct this test in a safe area. If the belt does not lock, remove
the belt mechanism assembly and conduct the following static
check. Also, whenever installing a new belt assembly, verify the
proper operation before installation.
2. Driver 's seat belt (ELR):
STATIC TEST
(a) Make sure that the belt locks when pulled out quickly.
(b) Remove the locking retractor assembly.
(c) Tilt the retractor slowly.
(d) Make sure that belt can be pulled out at a tilt of 15 degrees
or less, and cannot be pulled out over 45 degrees of tilt.
lf a problem is found, replace the assembly.
3. Except driver's seat belt (ALR/ELR):
STATIC TEST
(a) Make sure that the belt locks when pulled out quickly.
(b) Remove the locking retractor assembly.
(c) Pull out the whole belt and measure the length of the
whole belt.
Then retract the belt slightly and pull it out again.
(d) Make sure that the belt cannot be extended further.
If a problem is found,replace the assembly.

AB0152
SST
AB0158
SSTBattery
H01580
SST
H15467H15471H16295
Driver's side:
Except driver's side:
BO±94
± BODYSEAT BELT PRETENSIONER
2001 PRIUS (RM778U)
(a) Check the functioning of SST.
CAUTION:
When activating the seat belt pretensioner, always use the
specified SST: SRS Airbag Deployment Tool.
SST
Driver's side: 09082±00700, 09082±00730
Except driver's side: 09082±00700, 09082±00740
(1) Connect the SST to the battery.
Connect the red clip of the SST to the battery posi-
tive (+) terminal and the black clip to the battery neg-
ative (±) terminal.
HINT:
Do not connect the yellow connector which will be connected
with the seat belt pretensioner.
(2) Press the SST activation switch, and check the LED
of the SST activation switch lights up.
CAUTION:
If the LED lights up when the activation switch is not being
pressed, SST malfunction is probable, so definitely do not
use the SST.
(3) Disconnect the SST from the battery.
(b) Disconnect the pretensioner connector.
Disconnect the pretensioner connector as shown in the
illustration.
NOTICE:
When handling the pretensioner connector, take care not
to damage the wire harness.
(c) Install the SST.
(1) Buckle the front seat belt and check that there is no
looseness and slack in the front seat inner belt and
front seat outer belt.

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.