fuel pump TOYOTA PRIUS 2001 Service Repair Manual

2001 PRIUS (EWD414U)
G ELECTRICAL WIRING ROUTING
Position of Parts in Body
A 23 ABS Speed Sensor Rear LH
A 24 ABS Speed Sensor Rear RH
B 15 Battery Blower Motor
B 16 Battery Blower Motor Controller
B 17 Battery ECU
B 18 Battery ECU
B 19 Battery Fan Relay
B 20 Buckle SW and Tension Reducer LH
B 21 Buckle SW RH and
Seat Belt Warning Occupant Detection Sensor
D 6 Door Courtesy SW Front LH
D 7 Door Courtesy SW Front RH
D 8 Door Courtesy SW Rear LH
D 9 Door Courtesy SW Rear RH
D 10 Door Lock Control SW Front RH
D 11 Door Lock Motor and Door Unlock Detection SW
Rear LH
D 12 Door Lock Motor and Door Unlock Detection SW
Rear RH
D 13 Door Lock Motor, Door Key Lock and Unlock SW and
Door Unlock Detection SW Front LH
D 14 Door Lock Motor, Door Key Lock and Unlock SW and
Door Unlock Detection SW Front RHF 14 Front Door Speaker LH
F 15 Front Door Speaker RH
F 16 Fuel Pump and Fuel Sender
F 17 Fusible Link Block No.2
F 18 Fusible Link Block No.2
H 15 High Mounted Stop Light
H 16 Hybrid Vehicle Battery
H 17 Hybrid Vehicle Battery
I 16 Interior Light
I 17 Interlock SW
J 30 Junction Connector
J 31 Junction Connector
J 32 Junction Connector
J 33 Junction Connector
L 2 License Plate Light LH
L 3 License Plate Light RH
L 4 Luggage Compartment Door Unlock SW
L 5 Luggage Compartment Light
L 6 Luggage Compartment Light SW

2001 PRIUS (EWD414U)
ENGINE CONTROL
120A MAIN
1C 1
D 11B 215A
AM2 1J 92C 2
2G 176AM2 IG2
ST2
32 512B 5
2G 11
1J 3
1K 3
BL 1A 2
EA 15A
EFI
32 51
1F 11A10 1A31A4 13 25
1F 12 1F13
IA2 4IA114
7 3
IGA C
B AIA1 19 A
AA A
FUSIBLE LINK
BLOCK NO. 2 F18
JUNCTION CONNECTORB J 4 A , J 5FUSIBLE LINK
BLOCK NO. 1D F1 2 C , F13
W±BW±B W±B W±BB±G B W±R W±R
B±W B±W
B±W
B B G±RB±R G±R
B±R
B B
BB
W±B
B
B±W
B±W
R±W
G± R
G± R
B
B B±W
B±W
A C
FUEL PUMP F1 6
CIR OPN
RELAY
EFI
RELAY FROM POWER SOURCE SYSTEM (
SEE PAGE 50)
IGNITION SW I15
IG2
RELAY
JUNCTION
CONNECTOR J17B
BATTERY
JUNCTION
CONNECTOR J 7
JUNCTION
CONNECTOR J 1
A
A
JUNCTION
CONNECTOR
IEBC1 8
A
W±BJ18
W±B W±B
M

2001 PRIUS (EWD414U)
ENGINE CONTROL
This system utilizes an engine control module and maintains overall control of the engine, transmission and so on. An outline
of the engine control is explained here.
1. INPUT SIGNALS
(1) Engine coolant temp. signal circuit
The engine coolant temp. sensor detects the engine coolant temp. and has a built±in thermistor with a resistance which
varies according to the engine coolant temp. thus the engine coolant temp. is input in the form of a control signal into
TERMINAL THW of the engine control module.
(2) Intake air temp. signal circuit
The intake air temp. sensor is installed in the mass air flow meter and detects the intake air temp., which is input as a
control signal into TERMINAL THA of the engine control module.
(3) Oxygen sensor signal circuit
The oxygen density in the exhaust gases is detected and input as a control signal into TERMINALS OX1A and OX1B of
the engine control module.
(4) RPM signal circuit
Camshaft position and crankshaft position are detected by the camshaft position sensor and crankshaft position sensor.
Camshaft position is input as a control signal to TERMINAL G2 of the engine control module, and engine RPM is input
into TERMINAL NE+.
(5) Throttle signal circuit
The throttle position sensor detects the throttle valve opening angle, which is input as a control signal into TERMINALS
VTA and VTA2 of the engine control module.
(6) Vehicle speed signal circuit
The vehicle speed signal from brake ECU, detects the vehicle speed and inputs a control signal into TERMINAL SPD of
the engine control module via the combination meter.
(7) Battery signal circuit
Voltage is constantly applied to TERMINAL BATT of the engine control module. When the ignition SW is turned on, the
voltage for engine control module start±up power supply is applied to TERMINAL +B of the engine control module via
EFI relay.
(8) Engine knock signal circuit
Engine knocking is detected by knock sensor and the signal is input into TERMINAL KNK1 of the engine control module
as a control signal.
2. CONTROL SYSTEM
*SFI system
The SFI system monitors the engine condition through the signals, which are input from each sensor to the engine
control module. The best fuel injection volume is decided based on this data and the program memorized by the engine
control module, and the control signal is output to TERMINALS #10, #20, #30 and #40 of the engine control module to
operate the injector. (Inject the fuel). The SFI system produces control of fuel injection operation by the engine control
module in response to the driving conditions.
*ESA system
The ESA system monitors the engine condition through the signals, which are input to the engine control module from
each sensor. The best ignition timing is detected according to this data and the memorized data in the engine control
module, and the control signal is output to TERMINALS IGT1, IGT2, IGT3 and IGT4. This signal controls the ignition coil
and igniter to provide the best ignition timing for the driving conditions.
*Fuel pump control system
The engine control module operation outputs to TERMINAL FC and controls the CIR OPN relay. Thus controls the fuel
pump drive speed in response to conditions.
3. DIAGNOSIS SYSTEM
With the diagnosis system, when there is a malfunctioning in the engine control module signal system, the malfunction
system is recorded in the memory. The malfunctioning system can then be found by reading the display (Code) of the
malfunction indicator lamp.
4. FAIL±SAFE SYSTEM
When a malfunction occurs in any system, if there is a possibility of engine trouble being caused by continued control based
on the signals from that system, the fail±safe system either controls the system by using data (Standard values) recorded in
the engine control module memory or else stops the engine.
SYSTEM OUTLINE

2001 PRIUS (EWD414U)
HYBRID VEHICLE
CONTROL ECU
KEY INTERLOCK
SOLENOID
HAZARD WARNING
SW
BUCKLE SW AND
TENSION REDUCER LHPARK/NEUTRAL
POSITION SW
WIRELESS DOOR
CONTROL RECEIVER
(
GND)
(
CG)
CIGARETTE LIGHTER
DOOR LOCK MOTOR,
DOOR KEY LOCK AND
UNLOCK SW AND DOOR
UNLOCK DETECTION
SW FRONT LH
(
E)
IG1 RELAY
FUEL PUMP AND
FUEL SENDER
EMPS ECU
POWER WINDOW
CONTROL SW REAR RH
DOOR LOCK MOTOR AND
DOOR UNLOCK
DETECTION SW
REAR RH
POWER WINDOW
CONTROL SW FRONT RH
(
EL) A/C AMPLIFIER
UNLOCK
WARNING SW
REMOTE CONTROL SW
SHIFT LOCK ECU
BUCKLE SW RH AND
SEAT BELT WARNING
OCCUPANT DETECTION
SENSOR
AIRBAG SENSOR
ASSEMBLY
TRANSPONDER
KEY COMPUTER
POWER WINDOW
MASTER SW
PTC HEATER
DAYTIME RUNNING
LIGHT RELAY
BRAKE ECU* 1 : W/ DAYTIME RUNNING LIGHT
* 2 : W/ NAVIGATION SYSTEM
BB11
IQ11
IG ID B D
A E
E
A D
BE
A D
B
IJ111
B A
A A
B A
A A A
A A
B B A
A A
A
A A
B
A AIG12
IJ110
IC11
IA15
IA11 AA
A
A
A
AA
A AAA A A E
EW±B
W±B W± B
W± B
W± B
W±B W±B
W± B
W± B
W± B
W± BW± B
W±B W±BW±B
W±B
W±B
W±B
W±B
W±B W±B
W±B W± B
JUNCTION CONNECTORB J22 , J23A
JUNCTION
CONNECTORB J24 , J25A
2D8
2E3
2K8
A JUNCTION CONNECTOR J10
(
E)
(
E)W±B W±B
W±B
W±B
W±B W±B
W±B
W± B
W± B
W± B W± BW± B
W± B
W± B W±B
W±B J11
JUNCTION
CONNECTOR
J17
JUNCTION
CONNECTOR W±B
(
*1)
(
GND4) (
GND3)W± B
W± B
W± B
COMBINATION SW B 3W± B
W± B W±B
W±B
W±B
(
E)
(
CG) (
EOM)
(
KLS±)
GATEWAY ECU
DATA LINK
CONNECTOR 3
W±B
BODY ECU
(
E2) (
UN±) (
TL)LIGHT CONTROL
RHEOSTAT
GATEWAY ECU E
E
W± B E
JUNCTION
CONNECTOR J21
W±B

L
CodePart Name Part NumberCodePart Name Part Number
2001 PRIUS (EWD414U) E10
Engine Control Module90980±11638
F 1Front Airbag Sensor LH90980±11856F 2Front Airbag Sensor RH90980±11 856
F 3Front Parking Light LH
F 4Front Parking Light RH90980±11162F 5Front Side Marker Light LH90980±11162
F 6Front Side Marker Light RH
F 7Front Turn Signal Light LH90980±11019F 8Front Turn Signal Light RH90980±11019
F 9Front Wiper Motor90980±11599
F10Fusible Link Block No.1
F11Fusible Link Block No.1±
F12Fusible Link Block No.1
F13Fusible Link Block No.190980±11775
F14Front Door Speaker LH90980±10935F15Front Door Speaker RH90980±10935
F16Fuel Pump and Fuel Sender90980±12164
F17Fusible Link Block No.290980±10916
F18Fusible Link Block No.290980±11775
G 1Gateway ECU90980±11911
H 1Headlight LH90980±11314H 2Headlight RH90980±11314
H 3Heated Oxygen Sensor (Bank 1 Sensor1)90980±11028
H 4Horn90980±10619
H 5Hydraulic Booster90980±10939
H 6Hydraulic Booster90980±10946
H 7Hazard Warning SW90980±11319
H 8Hazard Warning SW90980±11921
H 9Heated Oxygen Sensor (Bank 1 Sensor 2)90980±11028
H10Hybrid Vehicle Control ECU90980±11638
H11Hybrid Vehicle Control ECU90980±11637
H12Hybrid Vehicle Control ECU90980±11586
H13Hybrid Vehicle Control ECU90980±11476
H14Hybrid Vehicle Control ECU90980±11421
H15High Mounted Stop Light90980±11060
H16Hybrid Vehicle Battery±H17Hybrid Vehicle Battery±
I 1Ignition Coil and Igniter No.1
I 2Ignition Coil and Igniter No.290980±11885I 3Ignition Coil and Igniter No.390980±11885
I 4Ignition Coil and Igniter No.4
I 5Injector No.1
I 6Injector No.290980±11875I 7Injector No.390980±11 875
I 8Injector No.4
I 9Inverter90980±11034
I10Inverter90980±10891
I11Inverter90980±10988
I12Inverter90980±10897
I13Inverter90980±11943
I14Inverter90980±11944
I15Ignition SW90980±11615
I16Interior Light90980±10860
I17Interlock SW90980±11918
J 1Junction Connector90980±10976
J 2Junction Connector90980±11742J 3Junction Connector90980±11742
J 4Junction Connector90980±11661J 5Junction Connector90980±11661
J6
Junction Connector (w/ Daytime Running
Light)90980±11542
J 6Junction Connector (w/o Daytime Running
Light)90980±11529
J 7Junction Connector90980±10803
J 8Junction Connector90980±11661J 9Junction Connector90980±11661
J10Junction Connector90980±11398
J11Junction Connector90980±10976
J12Junction Connector
J13Junction Connector90980±11661J14Junction Connector90980±11661
J15Junction Connector
J16Junction Connector90980±11915
J17Junction Connector90980±10976
J18Junction Connector90980±11661J19Junction Connector90980±11661
J20Junction Connector90980±11915J21Junction Connector90980±11915
J22Junction Connector
J23Junction Connector90980±11661J24Junction Connector90980±11661
J25Junction Connector
J26Junction Connector
J27Junction Connector90980±11915
J28Junction Connector
J29Junction Connector90980±11396
J30Junction Connector
J31Junction Connector90980±11661J32Junction Connector90980±11661
J33Junction Connector
K 1Knock Sensor90980±11166
L 1Light Control Rheostat90980±10797

2001 PRIUS (EWD414U)
M OVERALL ELECTRICAL WIRING DIAGRAM
1
234
2 PRIUS(
Cont. next page)
1C
1D1B 215A
AM2 1J 9
2 1
3 5
2 1
3 5
15A
EFI
1K 31F11A10 1F 12 1F13 1A31A4 1A 2
1B2H 12D 9
15A
THRO1J 3 1A 8
14 IA1 4IA2
7 3
M
IG Cowl si de
panel RH IE Cowl si de
panel LHCA
ABC
E
M
N G
I
J
K D
3B 4B
1 2
5 3
EFI
REL AY CIR OPN
RELAY
2ACC
IG1
ST1
IG2
ST2 AM1 4
6 7AM2
5
2B11
2G
7. 5A OBDII5A AM1
2B 3
2 1
5 3 2D 6
10A GAUGE
2A 5
22 AB
H
L F
2C 5A
7. 5A ECU±B
1
2G 2
2C
B± G
W B±Y
W± G
W± L
R± GIG1 RELAY IG2 RELAY
B± YB±WG± RGR
L
G± RB± R G± RB
B R± W
W± BB±R
G±R
W±B W±BW±B
L W± R
B± WR±G
W± L
B
B± W
B± W
GR
G± R
R± W
G± R
G± R
GR± B
B
B
B± W
B
BB± W
120A MAI NBATTERY F18
FUSI BLE
LINK BLOCK
NO. 2 1
A A
A F11 F12,
FUSIBLE
LI NK BLOCK NO. 1BCDF13 , 100A
DC/ DCI15
IGNITION SW W±R
J 7
JUNCTI ON
CONNE CTOR
J 1
J UNCTI ON
CONNE CTORAF1 6
FUEL
PUMP
J17
JUNCTI ON
CONNE CTOR
JUNCTI ON
CONNECTORB A J 4 J 5,
19 IA1 CA B2B GR
11
4
A 7
A/ C AMPLI FI ER
MP2 + MPX + MPX + MPX ± 16
15GR± B
GR
B
DD
J26
J UNCTI ON CONNECTOR W±L
C1 0 C11,
COMB I NATI ON
METERAB
B 8
BODY ECU
Engine Control
2K 8
ID Cowl side
panel LHJ11
JUNCTI ON
CONNECTOR A2D 8
W± B
O
W±B
W±BW±B
Power Source
GR
MAL FUNCTI ON
INDICATOR LAMP
B±W
BL Near the
f uel tankA A
8BC1J18
J UNCTI ON
CONNE CTOR W± B
W±B
A
W±B W±B
14 A
IHRight kick panel 2A 7
2B 6
LBR

ENGINE ± 1NZ-FXE ENGINE
182EG05
FrontExhaust Side
Crankshaft Center
Bore Center
8 mm
Intake Side12 mm
182EG06
Taper Squish Shape47
2. Cylinder Block

A cylinder block made of aluminum alloy has been adopted to realize a significant amount of weight reduc-
tion.

A water pump swirl chamber and an inlet passage to the pump are provided in the cylinder block.

The rear portion of the cylinder block has been shaped conically to improve the coupling rigidity with the
transaxle.

Through the adoption of the offset crankshaft, the bore center has been shifted 12 mm towards the intake,
in relation to the crankshaft center. Thus, the side force when the maximum pressure is applied has been
reduced and the heat efficiency has been improved. And as a result, fuel economy has been improved.

Through the use of a thin-walled cast iron liner in the cylinder bore, a distance of 8 mm between the bores
has been realized, resulting in a compact package. This liner is thin, so that boring is not possible.

By discontinuing the use of the rear oil seal retainer and by pressing the rear oil seal into the cylinder block,
a compact package has been realized.
3. Piston

The taper squish shaped piston has been
adopted to improve combustion chamber.

Low-tension piston rings have been adopted to
reduce friction and improve fuel economy and
oil consumption performance.

By increasing the mechining precision of the
cylinder bore diameter, the outer diameter of
the piston has been made into the one type.

ENGINE ± 1NZ-FXE ENGINE
182EG38
Injector
Delivery Pipe
Pressure Regulator
Fuel Tank Fuel Filter
Fuel Pump 58
FUEL SYSTEM
1. Injector
A compact 12-hole type injector has been adopted to improve the atomization of fuel.
2. Fuel Returnless System
This system is to reduce the evaporative emission. As shown below, integrating the pressure regulator and
fuel filter with the fuel pump assembly made it possible to discontinue the return of fuel from the engine area
and prevent temperature rise inside the fuel tank.
3. Quick Connector
Quick connector has been adopted to connect the fuel pipe with the fuel hose to improve serviceability.

ENGINE ± 1NZ-FXE ENGINE
182EG19
Air CleanerIntake Air Chamber
VSV (for EVAP)
ECM
VSV (for Purge Flow
Switching Valve)
Charcoal Canister
Vapor Pressure
Sensor
VSV (for Canister Closed Valve) Fuel Inlet Pipe Fuel: Vapor
: Fuel59
4. ORVR System
The ORVR (On-Board Refueling Vapor Recovery) is a system that uses a charcoal canister, which is provided
onboard, to recover the fuel vapor that is generated during refueling. This reduces the discharge of fuel vapor
into the atmosphere.
5. Fuel Tank
General
To reduce the amount of fuel vapor generated when the vehicle is parked, during refueling, or while driv-
ing, a vapor reducing fuel tank system has been adopted.
This system provides a vapor reducing fuel tank that expands or contracts in accordance with the volume
of the fuel in the fuel storage area in the fuel tank. By thus reducing the space in which fuel can evaporate,
the generation of fuel vapor is minimized.
Along with the provision of the vapor reducing fuel tank whose size fluctuates in the fuel tank, the fuel
gauge and the fuel pump have been provided in the sub tank. For this reason, a direct-acting fuel gauge
has been adopted.
NOTE:At low ambient temperatures, the capacity of the vapor reducing fuel tank is reduced as it is
made of resin (When the outside temperature is at ±10C (14F) the size of the tank will be re-
duced by approximate 5 liters).

ENGINE ± 1NZ-FXE ENGINE62
ENGINE CONTROL SYSTEM
1. General
The engine control system for the 1NZ-FXE engine has following system.
System
Outline
SFI
Sequential Multiport
Fuel InjectionAn L-type SFI system directly detects the intake air volume with a hot-wire
type mass air flow meter.
ESA
Electronic Spark
AdvanceIgnition timing is determined by the ECM based on signals from various
sensors. The ECM corrects ignition timing in response to engine knocking.
VVT-i
Variable Valve
Timing-intelligentControls the intake camshaft to an optimal valve timing in accordance with
the engine condition.
ETCS-i
Electronic
Throttle Control
System-intelligentOptimally controls the throttle valve opening in accordance with the ECM,
and the conditions of the engine and the vehicle, and comprehensively
controls the ISC and cruise control system.
Fuel Pump Control
Fuel pump operation is controlled by signal from the ECM.

To stop the fuel pump during operation of the SRS airbag.
Oxygen Sensor Heater
ControlMaintains the temperature of the oxygen sensors at an appropriate level to
increase accuracy of detection of the oxygen concentration in the exhaust gas.
Evaporative Emission
Control

The ECM controls the purge flow of evaporative emissions (HC) in the
charcoal canister in accordance with engine conditions.

Using 3 VSVs and a vapor pressure sensor, the ECM detects any
evaporative emission leakage occurring between the fuel tank and the
charcoal canister, and vapor reducing fuel tank through the changes in the
tank pressure. For details, see page 79.
Toyota HCAC System
The ECM controls the VSV (for Toyota HCAC System) to improve the clean
emission performance of the exhaust gas when the temperature of the TWC
is low. For details, see page 58.
Air Conditioning
Cut-Off ControlBy turning the air conditioning compressor OFF in accordance with the
engine condition, drivability is maintained.
Cooling Fan ControlRadiator cooling fan operation is controlled by signals from ECM based on
the engine coolant temperature sensor signal (THW).
HV Immobiliser
Prohibits fuel delivery, ignition, and starting the HV system if an attempt is
made to start the HV system with an invalid ignition key. For details, see page
80.
DiagnosisWhen the ECM detects a malfunction, the ECM diagnoses and memorizes
the failed section.
Fail-SafeWhen the ECM detects a malfunction, the ECM stops or controls the engine
according to the data already stored in memory.