O2 sensor TOYOTA PRIUS 2001 Service Repair Manual

BR1JL±01
F12503
F08657
SST
SST
BoltBolt
F12076
BR±56
± BRAKEREAR SPEED SENSOR
2001 PRIUS (RM778U)
REMOVAL
1. REMOVE REAR WHEEL
2. DISCONNECT SPEED SENSOR CONNECTOR
Disconnect the connector from the speed sensor.
3. REMOVE SPEED SENSOR WITH REAR AXLE HUB
(See page SA±46)
4. REMOVE SPEED SENSOR
(a) Using a pin punch and hammer, drive out the 2 pins and
remove the 2 attachments from SST.
SST 09520±00031
(b) Mount the rear axle hub in a soft jaw vise.
NOTICE:
Replace the axle hub assembly if it is dropped or a strong
shock is given to it.
(c) Using SST and 2 bolts (Diameter: 12 mm, Pitch: 1.5 mm),
remove the speed sensor.
SST 09520±00031 (09520±00040, 09521±00020),
09950±00020
NOTICE:

If a damage is inflicted to the sensor rotor, replace the
axle hub assembly.

Do not scratch the contacting surface of axle hub and
speed sensor.
5. IF NECESSARY, REPLACE SPEED SENSOR WIRE
HARNESS
(a) Remove the seat cushion, seatback and quarter trim
(See page BO±83).
(b) Disconnect the speed sensor wire harness connector.

± BRAKEREAR SPEED SENSOR
BR±57
2001 PRIUS (RM778U)
(c) Remove the 2 bolts, 2 nuts holding the sensor harness
from the lower arm and body.
Torque: 5.5 N´m (56 kgf´cm, 49 in.´lbf)
(d) Replace the sensor wire harness with the grommet.

F12217
Torx ScrewTorx Screw
Case
SR±16
± STEERINGTILT STEERING COLUMN
2001 PRIUS (RM778U)
(c) Install the steering wheel pad after confirming that the cir-
cumference groove of the torx screws is caught on the
screw case.
(d) Using a torx socket wrench, torque the 2 screws.
Torque: 8.8 N´m (90 kgf´cm, 78 in.´lbf)
19. CHECK STEERING WHEEL CENTER POINT
20. PERFORM CALIBRATION OF TORQUE SENSOR
ZERO POINT (See page DI±454)

F12196
F12214
Matchmarks
A
B
SR±26
± STEERINGELECTRIC POWER STEERING GEAR
2001 PRIUS (RM778U)
4. CONNECT EMPS BRACKET AND 2 CONNECTORS
(a) Connect the EMPS bracket with the 2 bolts.
Torque: 5.5 N´m (60 kgf´cm, 52 in.´lbf)
(b) Connect the earth wire with the bolt.
Torque: 5.5 N´m (60 kgf´cm, 52 in.´lbf)
(c) Connect the 2 clamps.
(d) Connect the 2 connectors.
5. CONNECT LOWER SUSPENSION ARM TO LOWER
BALL JOINT (See page SA±43)
6. CONNECT STABILIZER BAR (See page SA±43)
7. CONNECT NO. 2 INTERMEDIATE SHAFT ASSEMBLY
(a) Put the dust seal back to the engine compartment side.
(b) Remove the vinyl tape from the serrated part of the control
valve shaft.
(c) Align the matchmarks on the No. 2 intermediate shaft as-
sembly and control valve shaft.
(d) Install the bolt ºBº and torque the bolt ºAº.
Torque: 35 N´m (360 kgf´cm, 22 ft´lbf)
8. CONNECT RH AND LH TIE ROD ENDS
(See page SA±14)
9. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
HINT:
Do it with the front of the vehicle jacked up.
10. CENTER SPIRAL CABLE (See page SR±14)
11. INSTALL STEERING WHEEL
(a) Align the matchmarks on the steering wheel and steering
column main shaft.
(b) Temporarily tighten the steering wheel set nut.
12. CHECK STEERING WHEEL CENTER POINT
13. TORQUE STEERING WHEEL SET NUT
Torque: 50 N´m (510 kgf´cm, 37 ft´lbf)
14. INSTALL STEERING WHEEL PAD (See page SR±14)
15. CHECK FRONT WHEEL ALIGNMENT
16. PERFORM CALIBRATION OF TORQUE SENSOR
ZERO POINT (See page DI±454)

RS0JO±06
± SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
RS±1
1600 Author: Date:
2001 PRIUS (RM778U)
SRS AIRBAG
PRECAUTION
CAUTION:

The PRIUS is equipped with SRS, which comprises a driver airbag, front passenger airbag and
side airbag. Failure to carry out service operations in the correct sequence could cause the SRS
to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a
mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when re-
quired. Before performing servicing (including removal or installation of parts, inspection or
replacement), be sure to read the following items carefully, then follow the correct procedures
described in the repair manual.

Work must be started 90 seconds after the ignition switch is turned to the ºLOCKº position and
the negative (±) terminal cable is disconnected from the battery.
(The SRS is equipped with a back±up power source so that if work is started within 90 seconds
from disconnecting the negative (±) terminal cable of the battery, the SRS may be deployed.)

Do not expose the steering wheel pad, front passenger airbag assembly, side airbag assembly,
airbag sensor assembly, front airbag sensor or side airbag sensor assembly directly to hot air
or flames.
NOTICE:

Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most impor-
tant source of information when troubleshooting. When troubleshooting the SRS, always in-
spect the DTCs before disconnecting the battery.

Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front
passenger airbag assembly, side airbag assembly, airbag sensor assembly, front airbag sen-
sor and side airbag sensor assembly should be inspected.
(See page RS±14, RS±28, RS±41, RS±53, RS±58 and RS±63)

Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.

Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.

Never disassemble and repair the steering wheel pad, front passenger airbag assembly, side
airbag assembly, airbag sensor assembly, front airbag sensor or side airbag sensor assembly
in order to reuse it.

If the steering wheel pad, front passenger airbag assembly, side airbag assembly, airbag sen-
sor assembly, front airbag sensor or side airbag sensor assembly has been dropped, or if there
are cracks, dents or other defects in the case, bracket or connector, replace it with new one.

Use a volt/ohmmeter with high impedance (10 kW/V minimum) for troubleshooting the system's
electrical circuits.

Information labels are attached to the periphery of the SRS components. Follow the instruc-
tions on the notices.

After work on the SRS is completed, perform the SRS warning light check (See page DI±497).

When the negative (±) terminal cable is disconnected from the battery, the memory of the clock
and audio system will be canceled. So before starting work, make a record of the contents mem-
orized in the audio memory system. When work is finished, reset the audio systems as they
were before and adjust the clock. To avoid erasing the memory in each memory system, never
use a back± up power supply from outside the vehicle.

If the vehicle is equipped with a mobile communication system, refer to the precaution in the
IN section.

RS0R8±01
H15220
R09725Spiral Cable
H15507
H15678
H15676
RS±2
± SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
2001 PRIUS (RM778U)
OPERATION
1. STEERING WHEEL PAD (with AIRBAG)
The inflater and bag of the SRS are stored in the steering wheel
pad and cannot be disassembled. The inflater contains a squib,
igniter charge, gas generator, etc., and inflates the bag when
instructed by the airbag sensor assembly.
2. SPIRAL CABLE (in COMBINATION SWITCH)
A spiral cable is used as an electrical joint from the vehicle body
side to the steering wheel.
3. FRONT PASSENGER AIRBAG ASSEMBLY
The inflater and bag of the SRS are stored in the front passen-
ger airbag assembly and cannot be disassembled. The inflater
contains a squib, igniter charge, gas generator, etc., and in-
flates the bag when instructed by the airbag sensor assembly.
4. SIDE AIRBAG ASSEMBLY
The inflater and bag of the SRS side airbag are stored in the
side airbag assembly and cannot be disassembled. The inflater
contains a squib, igniter charge, gas generator, etc., and in-
flates the bag when instructed by the side airbag sensor assem-
bly.
5. SEAT BELT PRETENSIONER
The seat belt pretensioner system is a component of the front
seat outer belt. The pretensioner contains a squib, gas genera-
tor, wire, piston, etc., and operates in the event of a frontal colli-
sion. The seat belt pretensioner cannot be disassembled.

H15218
H15513
H15517
H15675
± SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
RS±3
2001 PRIUS (RM778U)
6. SRS WARNING LIGHT
The SRS warning light is located on the combination meter. It
goes on to alert the driver of trouble in the system when a mal-
function is detected in the airbag sensor assembly self±diagno-
sis. In normal operation conditions when the ignition switch is
turned to the ON position, the light goes on for about 6 seconds
and then goes off.
7. AIRBAG SENSOR ASSEMBLY
The airbag sensor assembly is mounted on the floor inside the
lower center finish panel. The airbag sensor assembly consists
of an airbag sensor, safing sensor, diagnosis circuit, ignition
control, drive circuit, etc. It receives signals from the airbag sen-
sor, front airbag sensor, side airbag sensor assembly and door
side airbag assembly and judges whether the SRS must be ac-
tivated or not. The airbag sensor assembly cannot be disas-
sembled.
8. FRONT AIRBAG SENSOR
The front airbag sensor is mounted inside each of the side
members. The sensor unit is a mechanical type. When the sen-
sor detects deceleration force above a predetermined limit,
contact is made in the sensor, sending a signal to the airbag
sensor assembly. The front airbag sensor cannot be disas-
sembled.
9. SIDE AIRBAG SENSOR ASSEMBLY
The side airbag sensor assembly is mounted in the LH and RH
center pillars. The side airbag sensor assembly consists of a lat-
eral deceleration sensor, safing sensor, diagnosis circuit, etc.
It sends signals to the airbag sensor assembly to judge whether
the SRS side airbag must be activated or not. The side airbag
sensor assembly cannot be disassembled.

H15711
Airbag
Sensor
AssemblySide Airbag Sensor
Assembly (RH)
Side Airbag
Assembly (RH) (Squib)
Seat Belt
Pretensioner (RH)
Front Airbag Sensor (RH)
Front Passenger Airbag
Assembly (Squib)
Steering Wheel
Pad (Squib)
Front Airbag Sensor (LH)
Side Airbag
Assembly (LH) (Squib) Seat belt
Pretensioner (LH) 10 7
8
9
11
6
5
1213
4
14
15
16
2
1
3
Spiral Cable
Side Airbag Sensor
Assembly (LH) RS±4
± SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
2001 PRIUS (RM778U)
10. SRS CONNECTORS
HINT:
SRS connectors are located as shown in the following illustra-
tion.
No.ItemApplication
(1)Terminal Twin±Lock MechanismConnectors 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16
(2)Airbag Activation Prevention MechanismConnectors 1, 2, 3, 4, 5, 6, 8, 9, 14, 15
(3)Electrical Connection Check MechanismConnectors 1, 2, 3

R12076Airbag Sensor AssemblyDisconnection
Detection
PinSRS
Warning
Light
H01315
Terminal for Diagnosis
Disconnection Detection Pin
Half Connection
Complete Connection
Terminal for
Diagnosis
RS±6
± SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
2001 PRIUS (RM778U)
HINT:
The type of connector is shown in the diagram on the previous
page.
(3) Electrical Connection Check Mechanism
This mechanism electrically checks that connectors
are connected correctly and completely. The electri-
cal connection check mechanism is designed so
that the disconnection detection pin connects with
the diagnosis terminals when the connector hous-
ing lock is locked.
HINT:
The illustration shows connectors º1º, º2º and º3º in step 11.

Z14034
Fig.1
Fig.2Power Source
Safing
Sensor
Squibs
Deceleration Sensor
H01581
Outer
H01582
Lock of connector is released
Disconnection is completed
± SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
RS±7
2001 PRIUS (RM778U)
(b) When the vehicle is involved in a frontal collision in the
hatched area (Fig. 1) and the shock is larger than the pre-
determined level, the SRS is activated automatically. A
safing sensor is designed to go on at a smaller decelera-
tion rate than the airbag sensor. As illustrated in Fig. 2,
ignition is caused when current flows to the squib, which
happens when a safing sensor and the deceleration sen-
sor go on simultaneously. When a deceleration force acts
on the sensors, 2 squibs in the driver airbag and front pas-
senger airbag ignite and generate gas. The gas discharg-
ing into the driver airbag and front passenger airbag rap-
idly increases the pressure inside the bags, breaking
open the steering wheel pad and instrument panel.
Bag inflation then ends, and the bags deflate as the gas
is discharged through discharge holes at the bag's rear or
side.
11. DISCONNECTION OF CONNECTORS FOR FRONT
AIRBAG SENSOR AND SIDE AIRBAG SENSOR
(a) While holding both flank sides of the outer, slide the outer
to the direction shown by an arrow.
(b) Lock of the connectors is released, then disconnect the
connectors.
HINT:
Be sure to hold both flank sides of the outer. If holding the top
and bottom sides, it will obstruct disconnection.