tow TOYOTA PRIUS 2001 Service Repair Manual

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.

CHASSIS ± SUSPENSION AND AXLES
No.2 Trailing
Arm Bushing
182CH35
Axle Beam
Trailing ArmNo.1 Trailing Arm
BushingToe-Control Link
Trailing Arm
No.2 Trailing Arm
Bushing
No.3 Trailing Arm Bushing
181CH35
Lengthwise ForceLateral Force
Lateral Force
Applied to
the Toe
Control Link
Bushing
Movement
Lateral Force
Toe Control
Links
Left-Side
WheelLeft-Side
Wheel97
Trailing Arm and Axle Beam

Trailing arms that are lightweight, highly rigid, hollow inside, and a gently curved axle beam with a rear-
open U-shaped cross section have been adopted.

A toe control links integrated axle beam has been adopted. The toe control link consists of the No.1, No.2,
and No.3 trailing arm bushings, and it rotates within the horizontal plane of the vehicle, around the No.3
bushing that serves as the axial center.

The rolling regidity has been optimized through the adoption of the stabilizer bar.
Toe-Correct Function
The longitudinal and lateral forces that are created in the vehicle during cornering causes the toe control
links in the trailing arms to become deformed.
On a right turn, the right trailing arm moves forward and the left trailing arm moves rearward, creating a
tendency for the left wheel to toe out.
In this situation, the toe control links that are installed in the trailing arms are designed to utilize the lateral
force, which is applied to the toe control links during cornering, to correct the left trailing arm towards the
toe-in direction.
As a result, excellent stability and controllability are realized.

BODY ELECTRICAL ± WIPER
182BE12
Idle Lever
Pivot Wiper Arm
Direction of Rotation
of Wiper MotorPivot
Wiper LinkMain Lever P
2P1
182BE13
Wiper Arm
P
2P1
Idle Arm P3Direction of Rotation
of Wiper Motor
182BE14
Wiper
Arm
P
2
P1Direction of Rotation
of Wiper Motor151
3. Operation

With the rotation of the wiper motor, the wiper link for driving wiper will operate and connection point
P
1 with the main lever will move toward the arrow mark by the influence of the wiper link with a pivot
as a supporting point. With this, the connection point P
2 between the wiper arm and the idle lever becomes
the supporting point of the pry and starts wiping by holding the arm upward.

In addition, when the wiper motor rotates, P
1 and P2 will move toward the arrow mark.
Then, the wiper arm with P
3 as a supporting point will rise by the influence of the idle arm as if expanding
upward to the left. With this, it enables to wipe wider range.

When the wiper motor rotates more, P
1 and P2 will move toward the arrow mark. The wiper arm with P2
as a supporting point will move toward contracting direction and wipe further to the upper reversal position.

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.

B04757
B04752
HV Fuse
IGCT Relay Engine Room J/B
Engine Room R/B No. 2
B04760
IN±18
± INTRODUCTIONFOR ALL OF VEHICLES
18 Author: Date:
2001 PRIUS (RM778U)

Remove the service plug with the insulated
gloves on.
If the service plug cannot be removed due to damage to the rear
portion of the vehicle, remove the HV fuse or IGCT relay
instead.
(c) Moving the damaged vehicle
HINT:
If any of the following applies, tow the vehicle away using a tow
truck lorry.

One or more of the high±voltage components and cables
is damaged.

The driving, traction, or fuel system is damaged.

The READY light is not lit when you turn ignition key to the
ON position.
NOTICE:

Before towing the vehicle away using a break down
lorry, disconnect the cable from the negative (±) ter-
minal of the auxiliary battery and remove the service
plug.
Only if none of the above applies and you see no prob-
lems that might affect the driving operation, you are
allowed to drive the vehicle away from the place of ac-
cident.

Preform the procedure below if the READY light goes
off or you detect an abnormal noise, abnormal smell,
or strong vibration while traveling:
(1) Park the vehicle in a safe place.
(2) Move the shift lever to the P position and engage
the parking brake.
(3) Disconnect the cable from the negative (±) terminal
of the auxiliary battery.
(4) Remove the service plug with insulated gloves on.

± INTRODUCTIONFOR ALL OF VEHICLES
IN±19
19 Author: Date:
2001 PRIUS (RM778U)
(d) Actions required after moving the damaged vehicle
If you see any liquid on the road surface, it could be the leakage
of the highly alkaline electrolyte.
Wearing rubber gloves and goggles, apply a red litmus paper
to the liquid. If the litmus paper turns blue, neutralize the liquid
using the saturated boric acid solution and reapply a red litmus
paper to make sure that it does not turn blue. Then wipe the liq-
uid off from the road surface using waste rags, etc.
(e) Items to be prepared (When repairing damaged vehicles)

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

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

Vinyl tape (For insulating cable)

Electrical tester
(f) Precautions to be observed when servicing the damaged
vehicle:
(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 the body ground using an electrical tes-
ter, and insulate the cable using a vinyl tape.
(3) Check the HV battery and nearby area for leakage.
If you find any liquid, it could be the leakage of the
highly alkaline electrolyte. Wear rubber gloves and
goggles, and then apply a red litmus paper to the
leak. If the litmus paper turns blue, neutralize the liq-
uid using the saturated boric acid solution and reap-
ply a red litmus paper to make sure that it does not
turn blue. Then wipe the liquid off using waste rags
etc.
(4) If the electrolyte adheres to your skin, wash the skin
immediately using the saturated boric acid solution
or large amounts of water. If the electrolyte adheres
to an article of clothing, take it off immediately.
(5) If the electrolyte comes into contact with your eyes,
call out loudly for help. Do not rub your eyes but
wash them with the saturated boric acid solution or
large amounts of water and seek medical care.

B04758
IN±20
± INTRODUCTIONFOR ALL OF VEHICLES
20 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.

Wear insulated gloves, and then remove the
service plug.

If you cannot remove the service plug due to
damage to the rear portion of the vehicle, re-
move the HV fuse or IGCT relay instead.
(g) Precautions to be taken when disposing of the vehicle
When scrapping the vehicle, remove the HV battery from
the vehicle and return it through the route specified by the
manufacturer. The same applies to any damaged HV bat-
tery.
(h) Precautions to be observed when towing
Tow the damaged vehicle with its front wheels or its front
and rear wheels lifted off the ground.
NOTICE:
Towing the damaged vehicle with its front wheels on the
ground may cause the motor to generate electricity. This
electricity could, depending on the nature of the damage,
leak and cause a fire.
(i) Towing with 4 wheels on the ground
NOTICE:

If you have to tow the damaged vehicle using a rope,
do it at a speed below 30 km/h. Such towing operation
is allowed only to cover very short distance, such as
the distance to a tow truck lorry, for example.

Set the ignition switch to the ACC position and shift
lever to the N position.

If you detect any abnormality in the damaged vehicle
during the towing operation, stop the towing opera-
tion immediately.
(j) Towing eyelet
(1) Install the hook.
(2) Hook a rope onto the illustrated point for towing.

B00061
New O±ring
CORRECT
WRONG Delivery Pipe
Injector
B00062
Delivery Pipe
SpacerO±ring
Grommet
B11839
Retainer
Pipe
Nylon Tube HousingO±Ring
B07690
SST
B11817
Retainer
(at 4 places)
± SFISFI SYSTEM
SF±3
1217 Author: Date:
2001 PRIUS (RM778U)
(b) Observe these precautions when removing and installing
the injector.
(1) Never reuse the O±ring.
(2) When placing a new O±ring on the injector, take
care not to damage it in any way.
(3) Coat a new O±ring with spindle oil or gasoline be-
fore installing never use engine, gear or brake oil.
(c) Install the injector to the delivery pipe and cylinder head,
as shown in the illustration. Before in installing the injec-
tor, must apply spindle oil or gasoline on the place where
a delivery pipe or a cylinder head touches on O±ring of the
injector.
(d) Observe these precautions when disconnecting the fuel
delivery pipe. The structure of the metallic connector is
shown as left.
(1) Remove the fuel pipe clamp.
(2) Get the metallic connector of the fuel tube assem-
bly, pull it out towards the rear and hold it as it is.
(3) Assemble SST to the connection as shown.
SST 09268±21010
(4) Turn SST, align the retainers inside the connector
with SST chamfered parts and incert SST into the
connector.

B11818
A13909
B11815
B00192
Vinyl Bag
S05382
Retainer
SF±4
± SFISFI SYSTEM
1218 Author: Date:
2001 PRIUS (RM778U)
(5) Hold SST as it at step 4, push the connector to-
wards SST to put the retainers on SST champfered
parts.
(6) Slide SST and the connector together towards the
fuel tube assembly.
(e) Observe these precautions when disconnecting the fuel
tube connector (quick type).
(1) Check if there is any dirt like mud on the pipe and
around the connector before disconnecting them
and clean the dirt away.
(2) Be sure to disconnect with hands.
(3) When the connector and the pipe are stuck, pinch
the retainer between the hands, push and pull the
connector to free to disconnect and pull it out. Do
not use any tool at this time.
(4) Inspect if there is any dirt or the likes on the seal sur-
face of the disconnected pipe and clean it away.
(5) Prevent the disconnected pipe and connector from
damaging and mixing foreign objects by covering
them with a vinyl bag.
(f) Observe these precautions when connecting the fuel
tube connector (quick type).
(1) Do not reuse the retainer removed from the pipe.
(2) Must use hands without using tools when to remove
the retainer from the pipe.
(3) Check if there is any damage or foreign objects on
the connected part of the pipe.

I17968
CO±18
± COOLINGRADIATOR AND CONDENSER MODULE
2001 PRIUS (RM778U)
8. REMOVE RADIATOR & CONDENSER MODULE
(a) Push the radiator & condenser module toward engine.
(b) Pull up the radiator until the lower radiator support is re-
moved.
(c) Pull it downward to remove it.