check engine light TOYOTA PRIUS 2001 Service Owner's Guide

EM1IY±02
A11249
Lod No.
A11228
84259
106137
A12126
Front90°90°
± ENGINE MECHANICALCYLINDER HEAD
EM±45
2001 PRIUS (RM778U)
INSTALLATION
HINT:

Thoroughly clean all parts to be assembled.

Before installing the parts, apply fresh engine oil to all slid-
ing and rotating surfaces.

Replace all gaskets and oil seals with new ones.
1. PLACE CYLINDER HEAD ON CYLINDER BLOCK
(a) Place a new cylinder head gasket on the cylinder block
surface with the Lod No. stamp upward.
NOTICE:
Be careful of the installation direction.
(b) Place the cylinder head quietly in order not to damage the
gasket with the bottom part of the head.
2. INSTALL CYLINDER HEAD BOLTS
HINT:

The cylinder head bolts are tightened in 2 progressive
steps (steps (b) and (d)).

If any cylinder head bolt is broken or deformed, replace
it.
(a) Apply a light coat if engine oil on the threads and under
the heads of the cylinder head bolts.
(b) Using a 10 mm bi±hexagon wrench, install and uniformly
tighten the 10 cylinder head bolts and plate washers, in
several passes, in the sequence shown.
Torque: 29.4 N´m (300 kgf´cm, 22 ft´lbf)
If any one of the cylinder head bolts does not meet the torque
specification, replace the cylinder head bolt.
(c) Mark the front of the cylinder head bolt with paint.
(d) Retighten the cylinder head bolts by 90° and 90° in the
numerical order shown.
(e) Check that the paint mark is now at a 180° angle to the
front.
(f) Install the bolt holding the water bypass pipe to the cylin-
der head.
Torque: 9.0 N´m (92 kgf´cm, 80 in.´lbf)

EM1J2±02
P08755
A13917
SSTSST
1
2
3
4
6
5
A13940
SST
A13917
SSTSST
1
2
3
4
6
5
EM±58
± ENGINE MECHANICALENGINE UNIT
2001 PRIUS (RM778U)
INSTALLATION
1. INSTALL FLYWHEEL
(a) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No. 08833±00070, THREE BOND 1324
or equivalent
(b) Install and uniformly tighten the new 6 bolts in several
passes, in the sequence shown.
Torque: 84 N´m (857 kgf´cm, 62 ft´lbf)
(c) Retighten the flywheel bolts by 90° in the numerical order
shown.
2. INSTALL DAMPER DISC
(a) Insert SST in the damper disc, then insert them in the fly-
wheel.
SST 09301±00110
HINT:
Take care not to insert damper disc in the wrong direction.
(b) Set the damper spring on the damper disc.
(c) Following the procedures shown in the illustration, tighten
the 6 bolts in the order starting the bolt locating near the
knock pin on the top.
Torque: 16 N´m (163 kgf´cm, 12 ft´lbf)
HINT:

Following the order in the illustration, tighten the bolts at
a time evenly.

Move SST up and down, right and left lightly, after check-
ing that the disc in the center, tighten the bolts.
3. INSTALL TRANSAXLE TO ENGINE
(a) Attach the transaxle to the engine, and install the 6 bolts.
Torque: 33 N´m (337 kgf´cm, 24 ft´lbf)
(b) Install the dust cover.
(c) Install the LH engine mounting bracket.
Torque: 52 N´m (530 kgf´cm, 38 ft´lbf)

A01205
A10456
EM±80
± ENGINE MECHANICALCYLINDER BLOCK
2001 PRIUS (RM778U)
(c) Install and uniformly tighten the 10 bolts of the bearing
cap is several passes, in the sequence shown.
Torque:
1ST 22 N´m (220 kgf´cm, 16 ft´lbf)
2ND Turn 90 °
(d) Check that the crankshaft turns smoothly.
7. CHECK CRANKSHAFT THRUST CLEARANCE
(See page EM±64)
8. INSTALL PISTON AND CONNECTING ROD
ASSEMBLES
Using a piston ring compressor, push the correctly numbered
piston and connecting rod assemblies into each cylinder with
the front mark of the piston facing forward.
9. PLACE CONNECTING ROD CAP ON CONNECTING
ROD
(a) Match the numbered connecting rod cap with the con-
necting rod.
(b) Align the pin dowels of the connecting rod cap with the
pins of the connecting rod, and install the connecting rod.
(c) Check that the protrusion of the connecting rod cap is fac-
ing in the correct direction.
10. INSTALL CONNECTING ROD CAP BOLTS
HINT:

The connecting rod cap bolts are tightened in 2 progres-
sive steps (steps (b) and (d)).

If any of the connecting rod cap bolts is broken or de-
formed, replace it.
(a) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(b) Install and alternately tighten the 2 connecting rod cap
bolts in several passes.
Torque:
1ST 15 N´m (150 kgf´cm, 11 ft´lbf)
2ND Turn 90 °
If any of the connecting rod cap bolts does not meet the torque
specification, replace the connecting rod cap bolts.
11. CHECK CONNECTING ROD THRUST CLEARANCE
(See page EM±64)

B00417
SST
B11832
Fuel Pump
Connector
B00679
Vinyl Bag
SF±2
± SFISFI SYSTEM
1216 Author: Date:
2001 PRIUS (RM778U)
(b) When installing the battery, be especially careful not to in-
correctly connect the positive (+) and negative (±) cables.
(c) Do not permit parts to receive a severe impact during re-
moval or installation. Handle all SFI parts carefully, espe-
cially the ECM.
(d) Be careful during troubleshooting as there are numerous
transistor circuit, and even slight terminal contact can
cause further troubles.
(e) Do not open the ECM cover.
(f) When inspecting during rainy weather, take care to pre-
vent entry of water. Also, when washing the engine
compartment, prevent water from getting on the SFI parts
and wiring connectors.
(g) Parts should be replaced as an assembly.
(h) Care should be taken when pulling out and inserting wir-
ing connectors.
(1) Release the lock and pull out the connector, pulling
on the connectors.
(2) Fully insert the connector and check that it is locked.
(i) Use SST for inspection or test of the injector or its wiring
connector.
SST 09842±30080
7. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large
amount of gasoline will spill out, so observe these proce-
dures.
(1) Disconnect the fuel pump connector.
(2) Start the engine. After the engine has stopped on
its own, turn the ignition switch to LOCK.
(3) Disconnect the fuel tube from the fuel tank.
(4) Drain the fuel remained inside the fuel tube.
(5) Prevent the disconnected fuel tube from damaging
and mixing foreign objects by covering them with a
vinyl bag.

BE±4
± BODY ELECTRICALTROUBLESHOOTING
1671 Author: Date:
2001 PRIUS (RM778U) Headlight flickers.
1. Bulb
2. Wire Harness±
±
Headlight is dark.1. Bulb
2. Wire Harness±
±
Taillight does not come on with light control switch in TAIL.1. Taillight Control Relay
2. Wire HarnessBE±20
±
Taillight does not go out with light control switch in OFF.1. Taillight Control Relay
2. Wire HarnessBE±20
±
Headlight does not come on with engine running and light control
switch in OFF.
1. ECU±B Fuse
2. GAUGE Fuse
3. Daytime Running Light Main Relay
4. Daytime Running Light Relay
5. Alternator L Terminal
6. Body ECU
7. Parking Brake Switch
8. Wire HarnessBE±12
BE±12
BE±20
BE±20
±
DI±678
BE±42
±
TURN SIGNAL AND HAZARD WARNING SYSTEM
SymptomSuspect AreaSee page
ºHazardº and ºTurnº do not light up.
1. GAUGE Fuse
2. TURN HAZ Fuse
3. Ignition Switch
4. Turn Signal Flasher Relay
5. Wire HarnessBE±12
BE±12
BE±17
BE±25
±
Hazard warning light does not light up.
(Turn is normal)1. Hazard Warning Switch
2. Wire HarnessBE±25
±
Turn signal does not light up.
(Hazard is normal)1. Turn Signal Switch
2. Wire HarnessBE±25
±
Turn signal does not light up in one direction.1. Turn Signal Switch
2. Wire HarnessBE±25
±
Only one bulb does not light up.1. Bulb
2. Wire Harness±
±
INTERIOR LIGHT SYSTEM
This system uses the multiplex communication system, so check diagnosis system of the multiplex commu-
nication system before you proceed with troubleshooting.
SymptomSuspect AreaSee page
All the lights do not come ON.DOME FuseBE±12
The driver door courtesy light does not come ON when the
driver's door is opened.1. Driver's Door Courtesy Switch
2. Wire Harness
3. Body ECUBE±27
±
±
The passenger door courtesy light does not come ON when the
passenger's door is opened.1. Passenger's Door Courtesy Switch
2. Wire Harness
3. Body ECUBE±27
±
DI±678
The room light does not come on when the rear±right door is
opened.
1. Rear±Right Door Courtesy Switch
2. Wire Harness
3. Body ECU
4. Room LightBE±27
±
DI±678
±
The room light does not come on when the rear±left door is
opened.
1. Rear±Left Door Courtesy Switch
2. Wire Harness
3. Body ECU
4. Room LightBE±27
±
DI±678
±
Only one of the bulbs comes ON.Bulb±

± BODY ELECTRICALTROUBLESHOOTING
BE±9
1676 Author: Date:
2001 PRIUS (RM778U)
POWER DOOR LOCK CONTROL SYSTEM
This system uses the multiplex communication system, so check diagnosis system of the multiplex commu-
nication system before you proceed with troubleshooting.
SymptomSuspect AreaSee page
All the doors cannot be locked or unlocked.
(Power Window Control System is normal.)1. Door Lock Control Switch
2. Body ECU
3. Wire HarnessBE±62
DI±678
±
Only one side door lock control does not operate.1. Door Lock Motor
2. Wire HarnessBE±62
±
Door key related function does not operate.
1. Door Key Lock and Unlock Switch
2. Body ECU
3. Wire HarnessBE±62
DI±678
±
Key confinement prevention function does not operate.
1. Key Unlock Warning Switch
2. Door Courtesy Switch
3. Body ECU
4. Wire HarnessBE±17
BE±27
DI±678
±
THEFT DETERRENT SYSTEM
This system uses the multiplex communication system, so check diagnosis system of the multiplex commu-
nication system before you proceed with troubleshooting.
HINT:
Troubleshooting of the theft deterrent system is based on the premise that the door lock control system is
operating normally. Accordingly, before troubleshooting the theft deterrent system, first make certain that
the door lock control system is operating normally.
SymptomSuspect AreaSee page
The theft deterrent system cannot be set
1. Indicator light circuit
2. ECU power source circuit
3. Key unlock warning switch circuit
4. Door key lock and unlock switch circuit
5. Door courtesy switch circuit
6. Door unlock detection switch circuit
7. Engine hood courtesy switch circuitDI±704
DI±685
DI±695
DI±724
DI±714
DI±710
DI±720
The indicator light does not blink when system is set.Indicator light circuitDI±704
When the system is set
(The system does not operate when the rear door is unlocked).Door unlock detection switch circuitDI±710
When the system is set
(The system does not operate when the luggage compartment
door is opened by a method other than the key).
Luggage compartment door courtesy switch circuitDI±722
When the system is set
(The system does not operate when the engine hood is lifted).Engine hood courtesy switch circuitDI±720
While the system is in warning operation
(Horns do not sound).Horn relay circuitDI±697
While the system is in warning operation
(Headlights do not flash).Headlight control relay circuitDI±693
While the system is in warning operation
(Taillights do not flash).Taillight control relay circuitDI±691
While the system is in warning operation
(The door lock is not locked).Door unlock detection switch circuitDI±710
System is still set even when a rear door is openDoor courtesy switch circuitDI±714
Even when the system is not set
(Horns sound).Horn relay circuitDI±697

I17791
0.4 °
3 m (9.84 ft) H 29.7 mm
(1.17 in.)
7
V RH Line
W90 °
V LH Line4
Low Beam:
V LH LineV Line V RH Line 65
6
29.7 mm
(1.17 in.)
High Beam:
V LH LineV Line V RH Line 6
5629.7 mm
(1.17 in.)
29.7 mm
(1.17 in.) H 4
O: step No.
7
H4
W
W
± BODY ELECTRICALHEADLIGHT AND TAILLIGHT SYSTEM
BE±23
2001 PRIUS (RM778U)
ADJUST HEADLIGHT AIM ONLY
(a) Place the vehicle in the following conditions.

The area around the headlight is not deformed.

The vehicle is parked on a level surface.

Tire inflation pressure is the specified value.

A driver is in the driver's seat and the vehicle is in
a state ready for driving (with a tank full).

The vehicle has been bounced several times.
(b) Check the headlight aiming.
(1) Prepare a thick white paper.
(2) Stand the paper perpendicular to the ground at the
position 9.84 ft away from the headlights.
(3) Ensure that the center line of the vehicle and the pa-
per face forms a 90±degree angle as shown in the
illustration.
(4) Draw a horizontal line (H line) on the paper, showing
where the headlights should strike.
(5) Draw a vertical line (V line) to where the center line
of the vehicle is to be.
(6) Draw 2 vertical lines (by connecting the low and
high beam center marks) to where the both head-
lights should strike (V RH and V LH lines).
(7) Draw a horizontal line (by connecting the both low
beam center marks) to where the headlights should
strike (H RH and H LH lines).
(8) Start the engine.
(9) Turn the headlights ON.
(10) Check that the headlights properly strike the posi-
tion shown in the illustration.
(11) If not, adjust the lights in the vertical direction.
HINT:
As shown in the illustration, adjust each aim of the RH and LH
lights.
(c) When adjusting it in the vertical direction:
Using adjusting bolt, adjust the headlight aim to within the
specified range.

I17865
Fuel Sender Gauge Connector
I17865
Fuel Sender Gauge Connector
I01277
BatteryWarning Light Ignition
Switch
Wire Harness Side
1
I01278
BE±44
± BODY ELECTRICALCOMBINATION METER
2001 PRIUS (RM778U)
5. INSPECT FUEL SENDER GAUGE VOLTAGE
Measure the voltage between terminals 1 and 6 for each fuel
level.
HINT:
The fuel sender gauge cannot be removed.
As the resistance value changes according to the remaining
fuel amount, refer to the above standard value.
Fuel levelResistance (W)
FullApprox. 430
HalfApprox. 1000 ± 2000
EmptyApprox. 5000
If resistance value is not as specified, replace the fuel tank.
If resistance value is as specified, replace the combination me-
ter.
6. INSPECT TEMPERATURE SENDER RESISTANCE
Measure the resistance between terminal 4 and 8
If the resistance value is not in the following area, replace fuel
tank.
1.5 ± 100 (W) at 0 ± 30°C
7. INSPECT LOW OIL PRESSURE WARNING LIGHT
(a) Disconnect the connector from the warning switch and
ground terminal of the wire harness side connector.
(b) Turn the ignition switch ON, check that the warning light
lights up.
If the warning light does not light up, test the bulb or inspect wire
harness.
8. INSPECT LOW OIL PRESSURE SWITCH CONTINUITY
(a) Check that continuity exists between terminal and ground
with the engine stopped.
(b) Check that no continuity exists between terminal and
ground with the engine running.
HINT:
Oil pressure should be over 24.5 kPa (0.25 kgf/cm
2, 3.55 psi)
If operation is not as specified, replace the switch.

BE1217
BatteryWarning Light
Ignition
Switch
I11650
BE0044
BatteryWarning Light
Ignition
Switch
Z11183
± BODY ELECTRICALCOMBINATION METER
BE±45
2001 PRIUS (RM778U)
9. INSPECT BRAKE WARNING SYSTEM LIGHT
(a) Disconnect the connector from the brake fluid warning
switch.
(b) Connect terminals of the wire harness side of the level
warning switch connector.
(c) Start the engine, check that the warning light lights up.
If the warning light does not light up, test the bulb or wire har-
ness.
10. INSPECT BRAKE FLUID LEVEL WARNING SWITCH
CONTINUITY
(a) Remove the reservoir tank cap and strainer.
(b) Disconnect the connector.
(c) Check that no continuity exists between terminals with the
switch OFF (float up).
(d) Use syphon, etc. to take fluid out of the reservoir tank.
(e) Check that continuity exists between terminals with the
switch ON (float down).
(f) Pour the fluid back in the reservoir tank.
If operation is not as specified, replace the switch.
11. INSPECT PARKING BRAKE WARNING LIGHT
(a) Disconnect the connector from the parking brake switch.
(b) Ground terminal of the wire harness side connector.
(c) Start the engine, check that the warning light lights up.
If the warning light does not light up, test the bulb or inspect wire
harness.
12. INSPECT PARKING BRAKE SWITCH CONTINUITY
(a) Check that continuity exists between terminal and switch
body with the switch ON (switch pin released).
(b) Check that no continuity exists between terminal and
switch body with the switch OFF (switch pin pushed in).
If operation is not as specified, replace the switch or inspect
ground point.