engine TOYOTA PRIUS 2001 Service Repair Manual

BR0K8±14
F12416
Reservoir
Brake Actuator HoseBrake Reservoir
Hose No. 2
Reservoir BracketRight Front Brake Line
ClipWiper Arm
Cowl Top Ventilator Louver RH
Hood to Cowl Top Seal
Outer Front Cowl Top PanelCowl Top Ventilator Louver LH
Brake Reservoir
Hose No. 1
Clamp

Non±reusable part: Specified torque
N´m (kgf´cm, ft´lbf)Clip
Clamp Bracket Engine Room R/B No. 2
15 (155, 11)
Lipuid and Suction Tube
Hydraulic Brake
Booster Assembly
19 (194, 14)
19 (194, 14)
Wiper Motor Cover
Sub±bracket
19 (194, 14)
19 (194, 14)
5.4 (55, 48 in.´lbf)
26 (270, 20)
7.4 (75, 64 in.´lbf)
7.5 (77, 66 in.´lbf)
Wiper Motor &
Link Assembly
18 (184, 13)
BR±42
± BRAKEHYDRAULIC BRAKE BOOSTER
2001 PRIUS (RM778U)
COMPONENTS

SR1BK±01
F12851
No. 2 Intermediate Shaft Assembly

Cotter Pin
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part
74 (760, 55)
35 (360, 26)
83 (850, 61)
49 (500, 36)

Cotter PinElectric Power
Steering Gear Assembly
Rack Housing
No. 2 Grommet
Rack Housing
No. 2 Bracket
83 (850, 61)
83 (850, 61)
74 (760, 55)
19 (190, 14)
19 (190, 14)Stabilizer Bar
142 (1450, 105)
142 (1,450, 105)
100 (1,020, 74)
137 (1,400, 101)
137 (1,400, 101)142 (1,450, 105)
137 (1,400, 101)
Suspension Member
LH Engine Under Cover
LH Engine Under Cover
49 (500, 36)
137 (4,400, 101)
Torque Rod
5.5 (60, 52 in.´lbf)5.5 (60, 52 in.´lbf)
EMPS Bracket





± STEERINGELECTRIC POWER STEERING GEAR
SR±17
1590 Author: Date:
2001 PRIUS (RM778U)
ELECTRIC POWER STEERING GEAR
COMPONENTS

SR1BL±01
F12196
F12214
A
B
± STEERINGELECTRIC POWER STEERING GEAR
SR±19
2001 PRIUS (RM778U)
REMOVAL
NOTICE:
Remove the steering wheel assembly before the steering
gear removal, because there is possibility of breaking of
the spiral cable.
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. REMOVE STEERING WHEEL PAD (See page SR±6)
3. REMOVE STEERING WHEEL (See page SR±6)
4. REMOVE RH AND LH ENGINE UNDER COVERS
5. DISCONNECT RH AND LH TIE ROD ENDS (See page
SA±9)
6. DISCONNECT STABILIZER BAR (See page SA±41)
7. DISCONNECT LOWER SUSPENSION ARM FROM
LOWER BALL JOINT (See page SA±41)
8. DISCONNECT 2 CONNECTORS AND EMPS BRACK-
ET
(a) Disconnect the 2 connectors.
(b) Disconnect the 2 clamps.
(c) Remove the bolt and disconnect the earth wire.
(d) Remove the 2 bolts and EMPS bracket.
9. DISCONNECT NO. 2 INTERMEDIATE SHAFT AS-
SEMBLY
(a) Place the matchmarks on the No. 2 intermediate shaft as-
sembly and control valve shaft.
(b) Loosen the bolt ºAº and remove the bolt ºBº then discon-
nect the No. 2 intermediate shaft assembly from the con-
trol valve shaft.
10. DISCONNECT TORQUE ROD (See page SA±41)
11. REMOVE SUSPENSION MEMBER AND ELECTRIC
POWER STEERING GEAR ASSEMBLY (See page
SA±41)
12. REMOVE ELECTRIC POWER STEERING GEAR AS-
SEMBLY
(a) Remove the stabilizer bar (See page SA±41).

SR1BO±01
F12847
Front
F12197
F15034
Serrated Part
F15035
Main Shaft Lower
Dust Seal
Body
Engine Compartment SideCab Side
± STEERINGELECTRIC POWER STEERING GEAR
SR±25
2001 PRIUS (RM778U)
INSTALLATION
1. INSTALL ELECTRIC POWER STEERING GEAR AS-
SEMBLY
(a) Install the grommet and bracket to the electric power
steering gear assembly.
HINT:
Install the bracket with the inscribed mark facing to the front of
the vehicle.
(b) Install the electric power steering gear assembly with the
4 new bolts to the front suspension member.
Torque: 83 N´m (850 kgf´cm, 61 ft´lbf)
(c) Install the stabilizer bar (See page SA±43).
(d) To prevent the main shaft lower dust seal from damaging,
wind vinyl tape on the serrated part of the control valve
shaft.
(e) Turn over the main shaft lower dust seal from the engine
compartment side to the cab.
2. INSTALL SUSPENSION MEMBER AND ELECTRIC
POWER STEERING GEAR ASSEMBLY (See page
SA±43)
3. CONNECT TORQUE ROD (See page SA±43)

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)

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±

BE±6
± BODY ELECTRICALTROUBLESHOOTING
1673 Author: Date:
2001 PRIUS (RM778U)
WIPER AND WASHER SYSTEM
SymptomSuspect AreaSee page
Wipers and washer do not operate.
1. WIPER Fuse
2. Wiper Switch
3. Wiper Motor
4. Wire HarnessBE±12
BE±34
BE±34
±
Wipers do not operate in LO, HI or MIST.
1. Wiper Switch
2. Wiper Motor
3. Wire HarnessBE±34
BE±34
±
Wipers do not operate in INT.
1. Wiper Switch
2. Wiper Motor
3. Wire HarnessBE±34
BE±34
±
Washer motor does not operate.
1. WASHER Fuse
2. Washer Switch
3. Washer Motor
4. Wire HarnessBE±12
BE±34
BE±34
±
Wipers do not operate when washer switch ON.
1. WASHER Fuse
2. Washer Switch
3. Wiper Motor
4. Wire HarnessBE±12
BE±34
BE±34
±
Washer fluid does not operate.Washer Hose and Nozzle±

When wiper switch is in HI position, the wiper blade is in contact
with the body.

When the wiper switch is OFF, the wiper blade does not retract
or the retract position is wrong.
1. Wiper Motor *1
2. Wire harness *1BE±34
±
*1: Inspect wiper arm and blade set positions.
Meter Gauges and Illumination:
COMBINATION METER
SymptomSuspect AreaSee page
Fuel Gauge and Water Temperature Gauge does not operate.
1. GAUGE Fuse
2. Meter Circuit Plate
3. Wire Harness±
BE±39
±
Speedometer does not operate.
1. Vehicle Speed Sensor
2. Meter Circuit Plate
3. Wire HarnessBE±42
BE±39
±
Tachometer does not operate.
1. Igniter
2. Engine and ECT ECU
3. Meter Circuit Plate
4. Wire Harness±
±
BE±39
±
Fuel Gauge does not operate or abnormal operation.1. Fuel Tank Assembly
2. Wire Harness±
±
All illumination lights do not light up.
1. TAIL Fuse
2. Meter Circuit Plate
3. Wire Harness±
BE±42
±
Only one illumination light does not light up.1. Bulb
2. Wire Harness±
±

± 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

BE1UY±02
I18844
Engine Room J/B No. 2 Relay Block
Instrument Panel
J/B
No. 3 Relay Block BE±12
± BODY ELECTRICALPOWER SOURCE
1679 Author: Date:
2001 PRIUS (RM778U)
POWER SOURCE
LOCATION

I17787
Engine room J/B:
Fuses:
1. HTR Fuse
2. RDI Fuse
3. ABS No. 2 Fuse
4. CDS FAN Fuse
5. HORN Fuse
6. THRO Fuse
7. ABS No. 3 Fuse
8. TURN±HAZ Fuse
9. AM2 Fuse
10. BATT FANRelays:
A. FAN NO. 1 Relay
B. FAN NO. 2 Relay
C. FAN NO. 3 Relay
D. IG2 Relay
E. HORN Relay
F. HTR Relay
G. EFI Relay
H. CLR MG Relay
I. HEAD Relay
J. CIR OPN Relay
K. DIM Relay *1
123 4 5 6 7 8
91011
121314
1516
17
18 K
J
A B
C D E
F
G H
I
11. DOME Fuse
12. HEAD HI (RH) Fuse *1
13. HEAD HI (LH) Fuse *1
14. HEAD LO (LH) *1
HEAD (LH) *2
15. HEAD LO (RH) *1
HEAD (RH) *2
16. EFI Fuse
17. HEV Fuse
18. HEAD Fuse *1
*1: w/ Daytime Running Light
*2: w/o Daytime Running Light
± BODY ELECTRICALPOWER SOURCE
BE±13
1680 Author: Date:
2001 PRIUS (RM778U)