engine TOYOTA PRIUS 2004 2.G Service Manual

271
Tire surface and wheel nuts
Check the tires carefully for cuts,
damage or excessive wear. See Sec-
tion 8
−2 for additional information.
When checking the tires, make sure
no nuts are missing, and check the
nuts for looseness. Tighten them if
necessary.
Tire rotation
Rotate the tires according to the
maintenance schedule. (For sched-
uled maintenance information, please
refer to the “Scheduled Maintenance
Guide” or “Owner ’s Manual Supple-
ment”.) See page 293 for additional
information.
Be on the alert for changes in perfor-
mance, sounds, and visual tip −offs that
indicate service is needed. Some impor-
tant clues are as follows:
Engine missing, stumbling, or pinging
Appreciable loss of power
Strange engine noises
A fluid leak under the vehicle (however,
water dripping from the air conditioning
after use is normal.)
Change in exhaust sound (This may
indicate a dangerous carbon monoxide
leak. Drive with the windows open and
have the exhaust system checked im-
mediately.)
Flat −looking tire; excessive tire squeal
when cornering; uneven tire wear
Vehicle pulls to one side when driving
straight on a level road
Strange noises related to suspension
movement
Loss of brake effectiveness; spongy
feeling brake pedal; pedal almost
touches floor; vehicle pulls to one side
when braking
Coolant temperature continually higher
than normal If you notice any of these clues, take your
vehicle to your Toyota dealer as soon as
possible. It probably needs adjustment or
repair.
CAUTION
Do not continue driving with the ve-
hicle unchecked. It could result in se-
rious vehicle damage and possibly
personal injury.
Does your vehicle need
repairing?

273
DOITYOURSELF MAINTENANCE
Introduction
Engine compartment overview274
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Fuse locations 275
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Do −it− yourself service precautions 276
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Positioning the jack 278
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Parts and tools 279
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SECTION 8– 1

274
Engine compartment overview
1. Windshield washer fluid tank
2. Brake fluid reservoir
3. Engine oil filler cap
4. Engine coolant reservoir
5. Inverter reservoir tank
6. Fuse block
7. Radiator and condenser
8. Engine oil level dipstick
9. Auxiliary battery
81p001g

276
If you perform maintenance by yourself,
be sure to follow the correct procedure
given in this Section.
You should be aware that improper or in-
complete servicing may result in operating
problems.
Performing do−it−yourself maintenance
during the warranty period may affect your
warranty coverage. Read the separate
Toyota Warranty statement for details and
suggestions.
This Section gives instructions only for
those items that are relatively easy for an
owner to perform. As explained in Section
7, there are still a number of items that
must be done by a qualified technician
with special tools.
For information on tools and parts for do −
it −yourself maintenance, see “Parts and
tools” on page 279.
Utmost care should be taken when work-
ing on your vehicle to prevent accidental
injury. Here are a few precautions that
you should be especially careful to ob-
serve:CAUTION
When the hybrid system is on, keep
hands, clothing, and tools away
from the moving fan and engine
drive belts. (Removing rings,
watches, and ties is advisable.)
Right after driving, the engine
compartment—the engine, radiator,
exhaust manifold and spark plug
boots, etc.—will be hot. So be care-
ful not to touch them. Oil, fluids
and spark plugs may also be hot.
If the hybrid system is hot, do not
remove the radiator cap or loosen
the drain plugs to prevent burning
yourself.
Do not leave anything that may
burn easily, such as paper or rags,
in the engine compartment.
Do not smoke, cause sparks or al-
low open flames around fuel or the
batteries. Their fumes are flam-
mable.
When the hybrid system is operat-
ing with the “READY” light on, the
engine is automatically started in
some case. When you inspect the
engine compartment, be sure to
press the “POWER” switch to the
“OFF” mode.
Do not get under your vehicle with
just the body jack supporting it. Al-
ways use automotive jack stands or
other solid supports.
Be sure that the hybrid system is
in the “OFF” mode if you work near
the electric cooling fans or radiator
grille. With the ignition on, the
electric cooling fans will automati-
cally start to run if the engine cool-
ant temperature is high and/or the
air conditioning is on.
Use eye protection whenever you
work on or under your vehicle
where you may be exposed to fly-
ing or falling material, fluid spray,
etc.
Be extremely cautious when work-
ing on the batteries. It contains poi-
sonous and corrosive sulfuric acid
or strong alkali.
Doityourself service
precautions

277
Used engine oil contains potentially
harmful contaminants which may
cause skin disorders such as in-
flammation or skin cancer, so care
should be taken to avoid prolonged
and repeated contact with it. To re-
move used engine oil from your
skin, wash thoroughly with soap
and water.
Do not leave used oil within the
reach of children.
Dispose of used oil and filter only
in a safe and acceptable manner.
Do not dispose of used oil and fil-
ter in household trash, in sewers or
onto the ground. Call your dealer
for information concerning recycling
or disposal.
Take care when filling the brake
fluid reservoir 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.
When servicing the vehicle with the
smart entry and start system, be
sure to keep the smart key away
from the vehicle. If the key is left
in the vehicle, the hybrid system
may start by pressing the “POWER”
switch with the brake pedal de-
pressed.
NOTICE
Remember that batteries and igni-
tion cable carry high currents or
voltages. Be careful of accidentally
causing a short circuit.
 Add only “Toyota Super Long Life
Coolant” or similar high quality eth-
ylene glycol based nonsilicate,
nonamine, nonnitrite, and nonbo-
rate coolant with longlife hybrid
organic acid technology to fill the
radiator. “Toyota Super Long Life
Coolant” is a mixture of 50% cool-
ant and 50% deionized water (for
the U.S.A.) or 55% coolant and 45%
deionized water (for Canada).
If you spill some of the coolant, be
sure to wash it off with water to
prevent it from damaging the parts
or paint.
 Do not allow dirt or anything else
to fall through the spark plug holes.
 Do not pry the outer electrode of
spark plug against the center elec-
trode.
 Use only spark plugs of the speci-
fied type. Using other types will
cause engine damage, loss of per-
formance or radio noise.
 If you spill the fluid, be sure to
wash it off with water to prevent it
from damaging the parts or paint.
 Do not drive with the air cleaner
filter removed, or excessive engine
wear could result. Also backfiring
could cause a fire in the engine
compartment.
 Be careful not to scratch the glass
surface with the wiper frame.
 When closing the hood, check to
see that you have not forgotten any
tools, rags, etc.

278
Positioning the jack
81p008d
Front
81p009d
Rear
When jacking up your vehicle with the
jack, position the jack correctly as
shown in the illustrations.
CAUTION
When jacking, be sure to observe the
following to reduce the possibility of
personal injury:
Follow jacking instructions.
Do not put any part of your body
under the vehicle supported by the
jack. Personal injury may occur.
Do not start or run the engine while
your vehicle is supported by the
jack.
Stop the vehicle on a level firm
ground, firmly set the parking brake
and put the transaxle in “P”.
Make sure to set the jack properly
in the jack point. Raising the ve-
hicle with jack improperly posi-
tioned will damage the vehicle or
may allow the vehicle to fall off the
jack and cause personal injury.
Never get under the vehicle when
the vehicle is supported by the jack
alone.
Do not raise the vehicle with some-
one in the vehicle.
When raising the vehicle, do not
place any objects on top of or un-
derneath the jack.
NOTICE
Make sure to place the jack correctly,
or your vehicle may be damaged.

279
Parts and tools
Here is a list of parts and tools you will
need to perform do−it−yourself mainte-
nance. Remember all Toyota parts are de-
signed in metric sizes, so your tools must
be metric.
CHECKING THE ENGINE OIL LEVEL
Parts (if level is low):
Engine oil API grade SL “Energy −Con-
serving” or ILSAC multigrade having
viscosity proper for your climate
Tools:
Rag or paper towel
Funnel (only for adding oil)
CHECKING THE COOLANT LEVEL
Parts (if level is low):
“Toyota Super Long Life Coolant” or
similar high quality ethylene glycol
based non− silicate, non −amine, non− ni-
trite, and non −borate coolant with long −
life hybrid organic acid technology.
“Toyota Super Long Life Coolant” is a
mixture of 50% coolant and 50% deion-
ized water (for the U.S.A.) or 55%
coolant and 45% deionized water (for
Canada).
Tools:
Funnel (only for adding coolant) CHECKING BRAKE FLUID
Parts (if level is low):
SAE J1703 or FMVSS No.116 DOT 3
brake fluid
Tools:
Rag or paper towel
Funnel (only for adding fluid)
CHECKING AUXILIARY BATTERY CON-
DITION
Tools:
Warm water
Baking soda
Grease
Conventional wrench (for terminal
clamp bolts)
CHECKING AND REPLACING FUSES
Parts (if replacement is necessary):
Fuse with same amperage rating as
original
ADDING WASHER FLUID
Parts:
Water
Washer fluid containing antifreeze (for
winter use) Tools:
Funnel
REPLACING LIGHT BULBS
Parts:
Bulb with same number and wattage
rating as original (See charts in “Re-
placing light bulbs–” on page 302.)
Tools:
Screwdriver

281
DOITYOURSELF MAINTENANCE
Engine and Chassis
Checking the engine oil level282
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Checking the coolant level 284
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Checking the radiator and condenser 286
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Checking brake fluid 286
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Checking and replacing the air conditioning filter 287
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Checking tire inflation pressure 289
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Checking and replacing tires 291
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Rotating tires 293
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Installing snow tires and chains 294
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Replacing wheels 295
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Aluminum wheel precautions 296
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SECTION 8– 2

282
82p001a
Low level Full level
Add oil O.K. Too full
With the hybrid system at operating
temperature and turned off, check the
oil level on the dipstick. 1. To get a correct reading, the vehicle should be on a level ground. After turn-
ing off the hybrid system, wait a few
minutes for the oil to drain back into
the bottom of the engine.
2. Pull the dipstick out, hold the rag un- der the end and wipe it clean.
3. Reinsert the dipstick—push it in as far as it will go, or the reading will not be
correct. 4. Pull the dipstick out and look at the oil
level while holding a rag under the
end.
CAUTION
Be careful not to touch the hot ex-
haust manifold.
NOTICE
Be careful not to drop engine oil on
the vehicle components.
If the oil level is below or only slightly
above the low level, add engine oil of
the same type as already in the engine.
Remove the oil filler cap and add engine
oil in small quantities at a time, checking
the dipstick. We recommend that you use
a funnel when adding oil.
The approximate quantity of oil needed to
raise the level between low and full on the
dipstick is indicated below for reference.
When the level reaches within the correct
range, install the filler cap hand− tight.
Oil quantity, L (qt., Imp. qt.): 1.5 (1.6, 1.3)
NOTICE
Be careful not to spill engine oil on
the vehicle components.
 Avoid overfilling, or the hybrid sys-
tem could be damaged.
 Check the oil level on the dipstick
once again after adding the oil.
Checking the engine oil level

283
ENGINE OIL SELECTION
“Toyota Genuine Motor Oil” is used in
your Toyota vehicle. Use Toyota approved
“Toyota Genuine Motor Oil” or equivalent
to satisfy the following grade and viscos-
ity.
Oil grade:API grade SL “Energy −Conserving” or
ILSAC multigrade engine oil.
Recommended viscosity:
SAE 5W −30
oil008
Outside temperature
SAE 5W30 is the best choice, for good
fuel economy, and good starting in cold
weather. If SAE 5W30 oil is not available, SAE
10W30 oil may be used. However, it
should be replaced with SAE 5W30 at
the next oil change.
82P103
API service symbol
ILSAC certification mark