engine TOYOTA PRIUS 2003 1.G Workshop Manual

218
If any of the above parts are extremely
dirty or you are not sure of their condi-
tion, take your vehicle to Toyota dealer.
CAUTION
To prevent yourself from burning, be
careful not to touch the radiator or
condenser when the engine is hot.
NOTICE
To prevent damage to the radiator
and condenser, do not perform the
work by yourself.
160.Checking brake fluid
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To check the fluid level, simply look at
the seethrough reservoir. The level
should be between the ”MAX” and
”MIN” lines on the reservoir.
It is normal for the brake fluid level to go
down slightly as the brake pads wear or
when the fluid level in the accumulator is
high.
If the reservoir needs frequent refueling,
it may indicate a serious mechanical prob-
lem.If the level is low, add SAE J1703 or
FMVSS No. 116 DOT 3 brake fluid to
the brake reservoir.
Refilling brake fluid:
1. Turn the ignition switch off.
2. Depress the brake pedal more than 40 times.
3. Remove the reservoir cap by hand. Add brake fluid up to the ”MAX” line.
If you do not follow the procedure above,
the reservoir may overflow.
Use only newly opened brake fluid. Once
opened, brake fluid absorbs moisture from
the air, and excess moisture can cause a
dangerous loss of braking.
CAUTION
Take care when filling the r eservoir
because brake fluid can harm your
eyes and damage painted surfaces. If
fluid gets in your eyes, flush your
eyes with clean water immediately. If
you still feel uncomfortable with your
eyes, go to the doctor.
159.Checking the radiator and
condenser

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If any washer does not work, the wash-
er tank may be empty. Check the wash-
er fluid level on the level gauge. If the
washer fluid level is below “LOW”, add
washer fluid.
“
FULL” on the side of the washer tank
indicates the full level of washer fluid. Do
not refill washer fluid over this level.
You may use plain water as washer fluid.
However, in cold areas where tempera-
tures range below freezing point, use
washer fluid containing antifreeze. This
product is available at your Toyota dealer
and most auto parts stores. Follow the
manufacturer ’s directions for how much to
mix with water.
NOTICE
Do not use engine antifreeze or any
other substitute because it may dam-
age your vehicle’s paint.
The following illustrations show how to
gain access to the bulbs. When replacing
a bulb, make sure the ignition switch and
light switch are off. Use bulbs with the
wattage ratings given in the table.
CAUTION
To prevent burning yourself, do not
replace the light bulbs while they
are hot.
Halogen bulbs have pressurized gas
inside and require special handling.
They can burst or shatter if
scratched or dropped. Hold a bulb
only by its plastic or metal case.
Do not touch the glass part of a
bulb with bare hands.
NOTICE
Only use a bulb of the listed type.
172.Adding washer fluid 173.Replacing light bulbs—

239
174.SPECIFICATIONS
Specifications
Dimensions and weight240
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Electric motor 240
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Enginee 240
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Fuel 241
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Hybrid vehicle battery 241
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Service specifications 241
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Tires 243
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Fuses 244
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SECTION 9

240
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
176.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: 1NZFXE
Type: 4cylinder 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)
175.Dimensions and weight 177.Engine

241
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)
179.Hybrid vehicle battery
Type: NickelMetal hydride battery
Voltage: 7.2 V
Capacity: 6.5 Ah (3HR)
Quantity: 38
Overall voltage: 273.6 V
180.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)
178.Fuel

242
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)
“Toyota Genuine Motor Oil” is f illed in your
Toyota vehicle. Use Toyota approved “Toyota
Genuine Motor Oil” or equivalent to satisfy the
following grade and viscosity.
Oil grade:
API grade SL “EnergyConserving” or
ILSAC multigrade engine oil. Recommended oil viscosity:
SAE 5W30
oil008
Temperature range anticipated before next
oil change
Please contact your Toyota dealer for further
details. 181.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 Genuine Long Life Coolant” is
filled in your Toyota vehicle. In order to
avoid technical problems, we strongly
recommend using “Toyota Genuine Long
Life Coolant” or equivalent.
Please contact your Toyota dealer for
further details.
With ethyleneglycol 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.

244
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Engine compartment
1. ABS NO.4 10 A: Antilock 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:
Righthand headlight (high beam)
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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: Righthand headlight
11. HEAD HI (LH) (Vehicles without DAY- TIME RUNNING LIGHT SYSTEM) 10
A: Lefthand headlight (high beam)
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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: Lefthand headlight
183.Fuses