Engine TOYOTA PRIUS 2002 1.G Workshop Manual

233
SPECIFICATIONS
Dimensions and weight234
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Electric motor 234
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Enginee 234
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Fuel 235
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Hybrid vehicle assembly 235
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Service specifications 235
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Tires 237
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Fuses 237
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SECTION 9

234
Overall length mm (in.) 4305 (169.5)
Overall width mm (in.) 1695 (66.7)
Overall height mm (in.) 1465 (57.6)*
Wheelbase mm (in.) 2550 (100.4)
Front tread mm (in.) 1475 (58.1)
Rear tread mm (in.) 1480 (58.2)
Vehicle capacity weight
(occupants + luggage)kg (lb.) 363 (800)
*: Unladen vehicle
Electric motor
Type: Permanent magnet motor (water cooling)
Rated output: 20 kW
Maximum output: 33.0/1040 − 5600 kW/rpm
Maximum torque: 350.0/0 − 400 N·m/rpm Model: 1NZ
−FXE
Type: 4 −cylinder in line, 4 cycle, gasoline
Bore and stroke, mm (in.): 75.0 x 84.7 (2.95 x 3.33)
Displacement, cm
3 (cu. in.):
1497 (91.4)
Dimensions and weight Engine

235
Fuel type:Unleaded gasoline, Octane Rating 87
(Research Octane Number 91) or
higher
Fuel tank capacity, L (gal., lmp. gal.): 45 (11.9, 9.9)
Hybrid vehicle battery
Type: Nickel −Metal hydride battery
Voltage: 7.2 V
Capacity: 6.5 Ah (3HR)
Quantity: 38
Overall voltage: 273.6 V
Service specifications
ENGINE
Valve clearance (engine cold), mm (in.): Intake 0.17—0.23 (0.007—0.009)
Exhaust 0.27—0.33 (0.011—0.013)
Spark plug type: DENSO SK16R11
NGK IFR5A11
Spark plug gap, mm (in.): 1.1 (0.043)
Fuel

236
ENGINE LUBRICATION
Oil capacity (drain and refill), L (qt, lmp.
qt.):
With filter 3.7 (3.9, 3.3)
Without filter 3.4 (3.6, 3.0)
Oil grade: API grade SJ “Energy −Conserving”, SL
“Energy −Conserving” or ILSAC
multigrade engine oil is recommended.
Recommended oil viscosity (SAE):
oil05u
COOLING SYSTEM
Total capacity, L (qt., Imp. qt.): For gasoline engine 4.9 (5.2, 4.3)
For electric motor
and inverter and
converter 2.6 (2.7, 2.3)
Coolant type: “TOYOTA Long Life Coolant” or equiva-
lent
With ethylene− glycol type coolant for a
proper corrosion protection of aluminum
components
Do not use alcohol type antifreeze or plain
water alone.
AUXILIARY BATTERY
Open voltage at 20 C (68 F):
12.6 − 12.8 V Fully charged
12.2 − 12.4 V Half charged
11 . 5 − 11.9 V Discharged
[Voltage that is checked 20 minutes after
the key is removed with all the lights
turned off]
Charging rates: 3.5 A max.HYBRID TRANSAXLE
Fluid capacity, L (qt., Imp. qt.):
4.6 (4.9, 4.1)
Fluid type: Automatic transmission fluid Type T −IV
or equivalent

237
BRAKES
Minimum pedal clearance when depressed
with the force of 196 N (20 kgf, 44 lbf)
with the traction motor running, mm (in.):80 (3.15)
Pedal free play, mm (in.): 1 − 6 (0.04 − 0.24)
Parking brake adjustment when depressed
with the force of 294 N (30 kgf, 66 lbf): 5 − 8 clicks
Fluid type: SAE J1703 or FMVSS No. 116 DOT 3
STEERING
Wheel free play: Less than 30 mm (1.2 in.)
Tires
Tire size and pressure:Tire size kPa (kgf/cm2 or bar, psi)
Standard
Front P175/65R14 84S 240 (2.4, 35)
Rear
P175/65R14 84S 230 (2.3, 33)
Spare
T125/70D16 96M 420 (4.2, 60)
Wheel size: Standard 14 x 5 1/2JJ
Spare 16 x 4T
Wheel nut torque, N·m (kgf·m, ft·lbf): 103 (10.5, 76)
NOTE: For a complete information on tires (e.g. replacing tires or replacing
wheels), see ”Checking tire pres-
sure” through ”Aluminum wheel
precautions”, page 214 through
219 in Section 8 −2.
90p005a
Engine compartment
1. ABS NO.4 10 A: Anti−lock brake sys-
tem
2. HTR NO.1 30 A: Air conditioning sys-
tem
3. HTR NO.2 30 A: Air conditioning sys-
tem
4. DRL 7.5 A: Daytime running light sys-
tem
5. CDS FAN 30 A: Air conditioning sys-
tem
6. HORN 10 A: Horn
7. HEAD HI (RH) (Vehicles with Daytime running light system only) 10 A:
Right −hand headlight (high beam)
Fuses

238
90p006a
Engine compartment
8. AM2 15 A: Starting system, multiport
fuel injection system/sequential multi-
port fuel injection system, hybrid ve-
hicle immobiliser system
9. THRO 15 A: Electronic throttle control
system
10. HEAD (RH) (Vehicles without DAY- TIME RUNNING LIGHT SYSTEM) or
HEAD LO (RH) (Vehicles with DAY-
TIME RUNNING LIGHT SYSTEM) 10
A: Right −hand headlight
11. HEAD HI (LH) (Vehicles without DAY- TIME RUNNING LIGHT SYSTEM) 10
A: Left −hand headlight (high beam)
90p007a
Instrument panel
12. BATT FAN 10 A: Battery cooling fan
13. ABS NO.3 20 A: Hydraulic brake
booster
14. HV 20 A: Hybrid system
15. EFI 15 A: Multiport fuel injection sys-
tem/sequential multiport fuel injection
system
16. HEAD (LH) (Vehicles without DAY- TIME RUNNING LIGHT SYSTEM) or
HEAD LO (LH) (Vehicles with DAY-
TIME RUNNING LIGHT SYSTEM) 10
A: Left −hand headlight
90p008a
Trunk
17. DOME 15 A: Audio system, mult −infor-
mation display, interior light, trunk light,
power window system, wireless remote
control system
18. TURNHAZ 10 A: Turn signal lights,
Emergency flasher
19. PANEL 5 A: Audio system, ashtray
light, headlight beam level control sys-
tem, emergency flasher
20. GAUGE 10 A: Gauge and meter, emer-
gency flasher, rear window defogger,
service reminder indicator and warning
buzzers, back− up light, power window
system, air c onditioning system

2
Quick index
If a service reminder indicator or warning buzzer comes on 91 . . . . .
 If your vehicle will not start 168 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 If your vehicle overheats 172 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
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 If you have a flat tire 173 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
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 If your vehicle needs to be towed 180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 Tips for driving during break-in period 146 . . . . . . . . . . . . . . . . . . . . . . . . . .
 How to start the hybrid system 162 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 General maintenance 195 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
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 Complete index NO TAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
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Gas station information
Fuel type:
UNLEADED gasoline, Octane Rating 87 (Research Octane Number 91)
or higher.
See page 146 for detailed information.
Fuel tank capacity:
45 L (11.9 gal., 9.9 lmp. gal.)
See page 146 for detailed information.
Engine oil:
API grade SJ, ”Energy −Conserving” or ILSAC multigrade engine oil
is recommended.
See page 209 for detailed information.
Automatic transmission fluid: Automatic transmission fluid Type T −IV or equivalent
Tire information: See pages 214 through 219.
Tire pressure: See page 237.