TOYOTA PRIUS 2001 Service Repair Manual

IN0CP±15
B04744
Front
JACK POSITION
Front crossmember
Body (Position shown in the illustration)
CAUTION :
When jacking±up the front and rear, make sure the vehicle is
not carrying any extra weight.
Do not position the jack at the center of the rear axle beam.
PANTOGRAPH JACK POSITION
SUPPORT POSITION
Safety stand and swing arm type lift Front
Rear



IN±8
± INTRODUCTIONREPAIR INSTRUCTIONS
2001 PRIUS (RM778U)
VEHICLE LIFT AND SUPPORT LOCATIONS

B04755
PLATE TYPE LIFT
L
B
AAttachment
C
HINT :
Left and right set position
Front and rear set positionPlace the vehicle over the center of the lift.

Align the cushion gum ends of the plate
with the attachment lower ends (A, C).

Align the attachment upper end (B) with the
front jack supporting point (L).
Attachment dimensions
85 mm (3.35 in.)
100 mm (3.94 in.)70 mm (2.76 in.)
200 mm (7.87 in.)
± INTRODUCTIONREPAIR INSTRUCTIONS
IN±9
2001 PRIUS (RM778U)

IN0HO±01
B04757
B04746
IN±10
± INTRODUCTIONFOR ALL OF VEHICLES
10 Author: Date:
2001 PRIUS (RM778U)
FOR ALL OF VEHICLES
PRECAUTION
1. PRECAUTIONS FOR HIGH±VOLTAGE CIRCUIT IN-
SPECTION AND SERVICE
(a) Engineers to be engaged in inspection and servicing re-
lated to high±voltage systems should undergo special
training.
(b) All the high±voltage wire harness connectors are colored
orange: the HV battery and other high±voltage compo-
nents are identified by the ºHigh Voltageº caution labels.
Do not carelessly touch these wires and components.
(c) Before inspecting or servicing the high±voltage system,
be sure to take measures such as wearing insulated
gloves and removing the service plug to prevent electro-
cution. Carry the removed service plug in your pocket to
prevent other technicians from reinstalling it while you are
servicing the vehicle.
(d) After removing the service plug, wait 5 minutes before
touching any of the high±voltage connectors and termi-
nals.
HINT:
The 5 minutes are required to discharge the high±voltage con-
denser inside the inverter.
(e) Before wearing insulated gloves, make sure that they are
not cracked, reptured, torn, or damaged in any other way.
Do not wear wet insulated gloves.
(f) When servicing the vehicle, do not wear a metal object
like a mechanical pencil or scale that may drop acciden-
tally and cause a short circuit.
(g) Before touching a bare high±voltage terminal, wear insu-
lated gloves and ensure that the terminal is not charged
with electricity (approx. 0 V) using an electrical tester.

B04747
± INTRODUCTIONFOR ALL OF VEHICLES
IN±11
11 Author: Date:
2001 PRIUS (RM778U)
(h) After disconnecting or exposing a high±voltage connec-
tor or terminal, insulate it immediately using insulation
tape.
(i) The screw of a high±voltage terminal should be tightened
firmly to the specified torque. Both insufficient and exces-
sive tightening torque can cause failure.
(j) Call other engineers' attention to the vehicle which high±
voltage system is being inspected or repaired by hanging
a ºHigh Voltage Operation in Progress. Do Not Touchº
sign (See the next page).
(k) After servicing the high±voltage system and before rein-
stalling the service plug, check again that you have not
left a part or tool inside, that the high±voltage terminal
screws are firmly tightened, and that the connectors are
correctly engaged.

CAUTION:
HIGH VOLTAGE. DO
NOT TOUCH DURING
OPERATION.
CAUTION:
HIGH VOLTAGE. DO
NOT TOUCH DURING
OPERATION.
Person in charge:
Person in charge:
Copy this page and put it after folding on the roof of the vehicle in service.B12120
IN±12
± INTRODUCTIONFOR ALL OF VEHICLES
12 Author: Date:
2001 PRIUS (RM778U)

B04748
B04749
1. +Terminal
2. +Terminal3. ±Terminal
4. ±Terminal
B04750
± INTRODUCTIONFOR ALL OF VEHICLES
IN±13
13 Author: Date:
2001 PRIUS (RM778U)
2. PRECAUTIONS TO BE OBSERVED WHEN INSPECT-
ING OR SERVICING ENGINE COMPARTMENT
The PRIUS, automatically turns the engine ON and OFF when
the ignition switch is set to the ON position provided that the
READY light on the instrument panel is it.
Before inspecting or servicing the engine compartment, there-
fore, remove the ignition switch key.
3. ACTIONS TO BE TAKEN WHEN BATTERIES ARE DE-
PLETED
(a) Actions to be taken when the auxiliary battery is depleted
HINT:
The following phenomena indicate that the auxiliary battery is
depleted:

No display appears on the instrument panel when you
turn the ignition switch to the ON position.

The hybrid system does not start.

The headlights are dark.

The sound from the horn is weak.
NOTICE:
Never use a quick charger.
(1) Move the shift lever to the P position, and engage
the parking brake.
(2) Remove the ignition key plate from the ignition
switch.
(3) Using a booster cable, connect the 12 V battery of
the rescue vehicle and auxiliary battery of the
stalled vehicle, as shown in the illustration.
(4) Start the engine of the rescue vehicle and run the
engine at a speed slightly higher than the idling
speed for 5 minutes to charge the auxiliary battery
of the stalled vehicle.
(5) Turn the ignition switch of the stalled vehicle to the
START position to start the hybrid system.
If the hybrid system fails to start and the master and HV battery
warning lights come on, the HV battery may have been dis-
charged.
(6) Disconnect the booster cable in the reverse way of
the connection procedure.
NOTICE:
If the auxiliary battery needs to be replaced, replace it only
with a 12 V battery specially designed for the use of the
PRIUS.

B04762
IN±14
± INTRODUCTIONFOR ALL OF VEHICLES
14 Author: Date:
2001 PRIUS (RM778U)
(b) Actions to be taken when HV battery is depleted
NOTICE:
Leaving a vehicle alone for 2 ± 3 months may cause electric
discharge from HV battery.
When this happens, replace the HV battery.
4. INSPECTION MODE
HINT:

The PRIUS automatically stops the engine while the ve-
hicle is stopped with the engine warmed up and battery
well charged if the A/C compressor operation is not re-
quired. Therefore, even if the vehicle stops for any reason
such as a check of ignition timing, the inspection mode
should be activated when continuous operation of the en-
gine is required.

The PRIUS has a skid control as traction control function.
When the wheel speed of the front wheels exceeds that
of the rear wheels, this function restrains the wheel speed
of the front wheels. It is necessary to activate the inspec-
tion mode and reset the skid control when turning only the
front wheels using a speedometer tester.
Activation inspection mode (Without using a hand±held tester)
(1) Perform the following (2) through (6) within 60 sec.
(2) Turn the ignition switch ON from OFF.
(3) With the shift lever in P position, fully depress the
accelerator pedal 2 times.
(4) With the shift lever in N position, fully depress the
accelerator pedal 2 times.
(5) With the shift lever in P position, fully depress the
accelerator pedal 2 times.
(6) Activate the inspecting mode and check that the hy-
brid system error warning light on the multi±center
display flashes.
(7) Turning the ignition switch to START starts the en-
gine's continuous operation.
NOTICE:

The idling speed in the inspection mode is approx.
1,000 rpm. The number of revolutions will increase up
to 1,500 rpm if the accelerator pedal is depressed to
a degree of less than 60%, and up to 2,250 rpm in a
case of 60% or more.

If a diagnosis code is recorded when entering the in-
spection mode, the master warning light and the error
warning light on the multi±center display is lit.

± INTRODUCTIONFOR ALL OF VEHICLES
IN±15
15 Author: Date:
2001 PRIUS (RM778U)

When the master warning light is lit during operation
in the inspection mode, deactivate the inspection
mode and inspect the diagnosed area.
HINT:
When continuous operation of the engine is required for such
as an exhaust leakage inspection, it is advisable as an easier
way to turn ON the FULL switch of the air conditioner.
5. SPECIAL NOTES FOR VEHICLE INSPECTION
(a) Vehicle conditions
(1) Before activating the service mode, turn the air con-
ditioner off, start the engine with the shift lever at P
position, and check that the engine stops within
several seconds after starting. (Engine warm up
check)
(2) Activate the service mode and inspect the vehicle.
The shift position for each test is as follows:
Test itemShift lever position
1. Vehicle straight traveling test (side
slip inspection)D
2. Braking force testN
3. Speedometer testD
4. Exhaust gas test (idling)P
5. Headlight testP
(3) Reset the service mode immediately after comple-
tion of inspection.
NOTICE:
Traveling on a road without resetting the service mode may
damage the transaxle.
(b) Special notes for speedometer test
NOTICE:
Rapid starting or quick acceleration/deceleration based on
the speedometer tester without load setting may damage
the transaxle.
(1) Depress the accelerator pedal slowly and gradually
accelerate at the time of measurement.
(2) After the measurement, use the brake to decelerate
gradually and stop.
(c) Special note for using the chassis dynamometer
Always set an appropriate load before starting the test.
NOTICE:
Rapid starting or quick acceleration/deceleration with in-
sufficient load may damage the transaxle.

IN±16
± INTRODUCTIONFOR ALL OF VEHICLES
16 Author: Date:
2001 PRIUS (RM778U)
6. ACTIONS TO BE TAKEN FOR VEHICLE DAMAGED BY
IMPACT
(a) Items to be prepared (For operation at the site of acci-
dent)

Protective clothing (Insulated gloves, rubber
gloves, goggles, and safety shoes)

Saturated boric acid solution 20 L (Procure 800 g of
boric acid powder, put it into a container, and dis-
solve it in water.)

Red litmus paper

ABC fire extinguisher (Applicable to both oil flames
and electrical flames)

Waste rags or old towels (For wiping off the electro-
lyte)

Vinyl tape (For insulating cable)

Electrical tester
(b) Actions to be taken at the place of accident
(1) Wear insulated or rubber gloves, goggles and safe-
ty shoes.
(2) Do not touch a bare cable that could be a high±volt-
age cable. If you need to touch it, or if you have a
danger of making an accidental contact, wear insu-
lated gloves, measure the voltage between the
cable and body ground using an electrical tester,
and insulate the cable using vinyl tape.
(3) If the vehicle catches fire, use a ABC fire extinguish-
er to extinguish the fire. Trying to extinguish the fire
using only a small amount of water can be more
dangerous than effective: either use a greater
amount of water from a fire hydrant or wait for the
fire fighters.
(4) If the vehicle is partially submerged in water, do not
touch the service plug or any of the high±voltage
components and cables because of the danger of
electrocution. If you need to touch them, do so only
after pulling the vehicle completely out of water.
(5) Check the HV battery and nearby area for any leak-
age of the electrolyte. Do not touch any leaking liq-
uid because it could be the highly alkaline electro-
lyte. If you need to wipe it off (using rags etc.), do so
only after completing the following procedure: wear
the rubber gloves and goggles, neutralize the elec-
trolyte with saturated boric acid solution, and finally
apply a red litmus paper to make sure that it does
not turn blue.

B04751
High±voltage Part and Wiring
Inverter and ConverterHV Battery
Power Cable
Hybrid Transaxle
± INTRODUCTIONFOR ALL OF VEHICLES
IN±17
17 Author: Date:
2001 PRIUS (RM778U)
(6) If a damage to any of the high±voltage components
and cables is suspected, cut the high±voltage cir-
cuit using the procedure below.

Move the shift lever to the P position and en-
gage the parking brake.

Remove the ignition key. Then disconnect the
cable from the negative (±) terminal of the
auxiliary battery.