TOYOTA PRIUS 2001 Service Repair Manual

CHASSIS ± STEERING
182CH66
182CH67
Instrument Panel
Reinforcement
Main ShaftInstrument Panel
Reinforcement
Energy Absorbing Plate
Breakaway Bracket
DetachSecondary
Collision
Primary
CollisionContractDeform
After Collision
Before Collision129
ENERGY ABSORBING MECHANISM
The energy absorbing mechanism in the steering column consists of a lower bracket, breakaway bracket, en-
ergy absorbing plate and a contractile main shaft. The steering column is mounted onto the instrument panel
reinforcement via a lower bracket and breakaway bracket which is supported via a capsule and energy absorb-
ing plate. The steering column and the steering gear box are connected with a contractile intermediate shaft.
Operational examples of this mechanism are follows.
When the steering gear box moves during a collision (primary collision), the main shaft and the intermediate
shaft contract, thus reduce the chance that the steering column and the steering wheel protrude into the cabin.
When an impact is transmitted to the steering wheel in a collision (secondary collision), the steering wheel
and the driver airbag help absorb the impact. In addition, the breakaway bracket and the lower bracket sepa-
rate, causing the entire steering column to move forward.
At this time, the energy absorbing plate becomes deformed to help absorb the impact of the secondary collision.

BODY ± BODY STRUCTURE
BODY
182BO01
: High Strength Sheet Steel 130
BODY STRUCTURE
DESCRIPTION
The Prius has adopted a body construction that achieves both high rigidity and safety.
LIGHTWEIGHT AND HIGHLY RIGID BODY
1. High Strength Sheet Steel
High strength sheet steel has been used in order to ensure body rigidity and realize a lightweight body.

BODY ± BODY STRUCTURE
182BO02A ± A Cross Section B ± B Cross Section C ± C Cross SectionC
C(D) (E)
A
BB
A
131
2. Body Shell

The joining construction (A-A cross section) of the cowl side panel, front pillar, and the instrument panel
reinforcement has been optimized to restrain the generation of vibrations.

By joining the under body and the front pillar with a pillar brace (B-B cross section), as well as the upper
end of the front pillar with the roof header (C-C cross section), the generation of vibrations has been re-
strained.

By providing a gusset (D) in the quarter wheel house and a reinforcement (E) in the upper back panel, the
generation of vibrations in the rear body area has been restrained.

BODY ± BODY STRUCTURE
182BO03

Impact Absorbing Structure for Front Collision 
Front
Impact
Energy 132
SAFETY FEATURES
1. Impact Absorbing Structure
General
The impact absorbing structure of the Prius provides a body construction that can effectively helps absorb
the energy of impact in the event of a front, or side collision. Also, it realizes a high level of occupant protec-
tion performance through the use of reinforcements and members that help to minimize cabin deformation.
Construction
1) Impact Absorbing Structure for Front Collision
In conjunction with the high level of impact absorbing structure for a front collision, the front bumper
reinforcement, the side members, the reinforcements and members that surround the cabin have been
optimally allocated.
Accordingly, the frameworks of the underbody and cabin help to absorb and dissipate the impact energy
efficiently, and to realize the minimized cabin deformation, in case of a front collision.

BODY ± BODY STRUCTURE
182BO04
182BO05

Impact Absorbing Structure for Side Collision 


Head Impact Protection Structure 
Energy Absorbing
Urethane PadEnergy Absorbing Material
Side Impact
Protection Beams
Side Impact Energy
Side Impact Protection Beam
: Energy Absorbing Rib
: Aluminum Energy
Absorbing Material133
2) Impact Absorbing Structure for Side Collision
Impact energy of a side collision directed to the cabin area is dispersed throughout the body via pillar
reinforcements, side impact protection beams, floor cross members, thus helping minimize the impact
energy finally directed to the cabin. In addition, the body is made reinforced joints and high strength
sheet steel, in order to help maintain the maximum preservation of the cabin space. And, in order to
make the door energy absorbent, a closed cross section configuration is provided at the belt line area
of the front and rear doors.
By providing an energy absorbing urethane pad in the front door panel and an energy absorbing mate-
rial in the door panel and the center pillar garnish, the impact of a collision can be dampened.
A head impact protection structure has been adopted. With this type of construction, if the occupant's
head hits against the roof side rail and pillar in reaction to a collision, the inner panel of the roof side
rail and pillar collapses to help reduce the impact.

BODY ± RUST-RESISTANT BODY
182BO06
: Anti-Corrosion Sheet Steel 134

RUST-RESISTANT BODY
1. General
Rust-resistant performance is enhanced by extensive use of anti-corrosion sheet steel and an anti-corrosion
treatment by applying wax, sealer and anti-chipping paint to easily corroded parts such as the hoods, doors
and rocker panels.
2. Anti-Corrosion Sheet Steel
Anti-corrosion sheet steel is used in all areas other than the roof and interior parts.

BODY ± RUST-RESISTANT BODY
182BO07
: Edge Seal
: PVC Coating
Area
182BO08
: Anti-Chipping Paint
: PVC Chipping Primer
135
3. Wax and Sealer
Wax and sealer are applied to the hemmed portions of the hoods, door panels, rocker panel and luggage
compartment door to improve rust-resistant performance.
4. Under Coat
PVC (Polyvinyl Chloride) coating is applied to the under side of the body.
The bottom side of the cowl panel, the fender apron and other parts which are subject to damage by stone
chipping.
5. Anti-Chipping Application
Anti-chipping paint and PVC chipping primer are applied to the lower quarter panel area, lower door panel
area, front hood area and the rocker panel area to protect them from stone chipping.

BODY ± LOW VIBRATION AND LOW NOISE BODY
182BO09
182BO10
: Roof Silenser Pad
Foamed Urethane
Sponge
: Foamed Seal Material
: Felt
Dash Panel Silencer
Floor Silencer (RSPP)
:
136
LOW VIBRATION AND LOW NOISE BODY
1. General
Effective application of vibration damping and noise suppresant materials reduces engine and road noise.
2. Sound Absorbing and Vibration Damping Materials

Adoption of the dash panel silencer made the reduction of the engine and road noise and improved the
quietness in the compartment.

Foamed urethane sponge, foamed seal material, felt and roof silencer pad are applied onto the roof panel
and pillars to reduce wind and road noise.

The adoption of the floor silencer realized the reduction of the engine and road noise. Also, the adoption
of RSPP (Recycled Sound Proof Products) for raw material realized the improvement of recylability.

BODY ± AERODYNAMICS
182BO12
182BO13
Front Fairing Rear Fairing137
AERODYNAMICS
DESCRIPTION
To improve aerodynamic performance, the following measures have been taken.

The shapes of the front pillar, outside rear view mirror, and the front windshield glass have been optimized
to achieve a smooth air flow.

The height and the shape of the front bumper have been optimized in order to rectify the airflow under the
floor and along the body sides.

The shapes of the engine undercover, fuel tank bottom surface, and the rear floor bottom surface have been
optimized to achieve a smooth underbody air flow.

A front and rear fairings are provided to smooth out the airflow around the tires and reduce the air resis-
tance while the vehicle is in motion.

BODY ± ENHANCEMENT OF PRODUCT APPEAL
182BO14
Phosphorescent
182BO15
A ± A Cross Section B ± B Cross Section CRS Lower AnchorageA
ACRS Anchor Bracket
CRS Anchor Bracket
Anchor Cover
Package
Tray Trim
Seat Back
CRS Lower
Anchorage
Seat CushionB
B 138
ENHANCEMENT OF PRODUCT APPEAL
INTERNAL TRUNK RELEASE HANDLE
An internal trunk release handle is included inside the trunk in case a person inadvertently locks himself with-
in the trunk and needs to free himself. The handle is made of phosphorescent so that it is visible in the trunk
for a while even after the trunk has been closed.
SEAT

CRS (Child Restraint System) lower anchorage for securing child seats, which complies with FMVSS225,
has been provided behind the seat cushion of both outer rear seats.

Three CRS anchor brackets for securing a child seat have been provided above the package tray trim.