engine TOYOTA PRIUS 2004 2.G Workshop Manual

284
Oil identification marks
Either or both API registered marks are
added to some oil containers to help
you select the oil you should use.
The API Service Symbol is located any-
where on the outside of the container.
The top portion of the label shows the oil
quality by API (American Petroleum Insti-
tute) designations such as SL. The center
portion of the label shows the SAE viscos-
ity grade such as SAE 5W−30. “Energy −
Conserving” shown in the lower portion,
indicates that the oil has fuel −saving ca-
pabilities.
The ILSAC (International Lubricant Stan-
dardization and Approval Committee) Certi-
fication Mark is displayed on the front of
the container.
To ensure excellent lubrication perfor-
mance for your engine, “Toyota Genuine
Motor Oil” is available, which has been
specifically tested and approved for all
Toyota engines.
Please contact your Toyota dealer for fur-
ther details about “Toyota Genuine Motor
Oil”.
CAUTION
The coolant heat storage tank reaches
high temperature inside. It is danger-
ous if hot coolant is discharged when
replacing. For replacement of the
coolant, contact your Toyota dealer.
Look at the seethrough coolant reser-
voir when the hybrid system is cold.
The coolant level is satisfactory if it is
between the “FULL” and “LOW” lines
on the reservoir. If the level is low, add
the coolant. (For the coolant type, see
“Coolant type selection” described be-
low.)
The coolant level in the reservoir will vary
with hybrid system temperature. However,
if the level is on or below the “LOW” line,
add coolant. Bring the level up to the
“FULL” line.
If the coolant level drops within a short
time after replenishing, there may be a
leak in the system. Visually check the
radiator, hoses, radiator cap and drain
cock and water pump.
Checking the coolant level

286
If any of the above parts are extremely
dirty or you are not sure of their condi-
tion, take your vehicle to a Toyota dealer.
CAUTION
To prevent burning yourself, be care-
ful not to touch the radiator or con-
denser when the engine is hot.
NOTICE
To prevent damage to the radiator
and condenser, do not perform the
work by yourself.
Checking brake fluid
82p002b
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 hybrid system 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.
NOTICE
If you spill the fluid, be sure to wipe
it off to prevent it from damaging the
parts or painting.
Checking the radiator and
condenser

302
If any washer does not work, the wash-
er tank may be empty. Add washer
fluid.
You may use plain water as washer fluid.
However, in cold areas where tempera-
tures range below the 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 hybrid system 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.
Vehicles with discharge headlights—
Do not touch the high voltage sock-
et when the headlight turns on.
20000 V is momentarily generated
and may cause severe injury by
electric shock.
Do not disassemble, repair or take
apart the headlight bulbs, connec-
tor, power supply circuits and ro-
tate components. Or you may be
injured by electric shocks. Call your
dealer when the headlights fail to
work or have to be replaced or dis-
posed of.
NOTICE
Only use a bulb of the listed type.
Adding washer fluid Replacing light bulbs—

309
SPECIFICATIONS
SPECIFICATIONS
Dimensions and weight310
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.
Electric motor 310
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. . . . . . . . . .
Enginee 310
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. . . . . . . . . . . . . . .
Fuel 311
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. . . . . . . . . . . . . . . . . . .
Hybrid vehicle battery 311
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. . .
Service specifications 311
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . .
Tires 313
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. . . . . . . . . . . . . . . . . .
Fuses 314
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SECTION 9

310
Overall length mm (in.) 4445 (175.0)
Overall width mm (in.) 1725 (67.9)
Overall height mm (in.) 1490 (58.7)*
Wheelbase mm (in.) 2700 (106.3)
Front tread mm (in.) 1505 (59.3)
Rear tread mm (in.) 1480 (58.3)
Vehicle capacity weight
(occupants + luggage)kg (lb.) 385 (845)
*: Unladen vehicle
Electric motor
Type: Permanent magnet synchronous motor (water cooling)
Maximum output: 50/1200 − 1540 kW/rpm
Maximum torque: 400/0 − 1200 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

311
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: 28
Overall voltage: 201.6 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

312
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 used 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 “Energy −Conserving” or
ILSAC multigrade engine oil. Recommended oil viscosity:
SAE 5W
−30
oil008
Outside temperature
Please contact your Toyota dealer for further
details. COOLING SYSTEM
Total capacity, L (qt., Imp. qt.):
For gasoline engine 8.6 (9.0, 7.5)
For electric motor
and inverter and
converter 2.7 (2.9, 2.4)
Coolant type: “Toyota Super Long Life Coolant” is
used in your Toyota vehicle at factory
fill. In order to avoid technical prob-
lems, only use “Toyota Super Long Life
Coolant” or similar high quality ethyl-
ene glycol based non −silicate, non −
amine, non− nitrite, and non− borate
coolant with long −life hybrid organic
acid technology. (Coolant with long −life
hybrid organic acid technology is a
combination of low phosphates and or-
ganic acids.)
Do not use plain water alone.
Please contact your Toyota dealer for
further details.

314
90p007b
Instrument panel
1. PWR 30 A: Power windows
2. DEF 40 A: Rear window defogger
3. M/HTR 15 A: Outside rear view mirror
heater
4. WIP 30 A: Windshield wiper
5. RR WIP 15 A: Rear wiper
6. WSH 20 A: Washer
7. ECUIG 7.5 A: Smart entry and start
system, power wi ndows, multi−informa-
tion display, electric power steering,
theft deterrent system
90p005b
Engine compartment
8. GAUGE 10 A: Gauge and meter, back −
up lights, emergency flasher, power
windows
9. OBD 7.5 A: On−board diagnosis sys-
tem
10. STOP 7.5 A: Stop lights
11. DOOR 25 A: Power door lock system
12. ACCB 25 A: “POWER OUTLET”,
“ACC” fuses
13. ECUB 15 A: Multi−information display,
power windows, air conditioning system
14. AM1 7.5 A: Hybrid system
90p008b
Luggage compartment
15. TAIL 10 A: Tail lights, license plates
light, parking lights
16. PANEL 7.5 A: Multi−information dis-
play, clock, audio system, instrument
panel lights
17. A/C (HTR) 10 A: Air conditioning sys-
tem
18. FR DOOR 20 A: Power windows
19. PWR OUTLET 15 A: Power outlet
20. ACC 7.5 A: Audio system, multi −infor-
mation display, clock
21. PWR OUTLET FR 15 A: Power outlet
Fuses

324
Important health andsafety information about your
To y o t a
CAUTION
WARNING: Engine exhaust, some of its constitu-
ents, and a wide variety of automobile compo-
nents contain or emit chemicals known to the
State of California to cause cancer and birth de-
fects and other reproductive harm. In addition,
oils, fuels and fluids contained in vehicles as well
as waste produced by component wear contain or
emit chemicals known to the State of California
to cause cancer and birth defects or other repro-
ductive harm.
Battery posts, terminals and related accessories
contain lead and lead compounds. Wash your
hands after handling. Used engine oil contains
chemicals that have caused cancer in laboratory
animals. Always protect your skin by washing
thoroughly with soap and water.

329
Precautions for useof hybrid vehicle
The vehicle has both high voltage
DC and AC systems as well as a
12volt system. DC and AC high
voltage are both very dangerous
and can cause death or serious inju-
ry, severe burns and electric shock.
In order to avoid personal in-
juries, do not touch the high
voltage cables (orange col-
ored) and their connectors.
Follow the caution labels at-
tached to the high voltage
parts.
Do not remove or replace the
high voltage parts such as
the inverter unit (located in
the engine compartment), hy-
brid vehicle battery (located
behind rear seat), etc.
Do not touch the service plug
located in the left side trim
of the luggage compartment
without hybrid system techni-
cal training. (See “Precau-
tions for use” on page 12 in
Section 12.) This component
is provided to disable the
high voltage system in case
of servicing at a Toyota deal-
er.
CAUTIONIf an accident occurs
Pull your vehicle off the road,
push the “P” position switch,
stop the hybrid system and if
the key is inserted into key
slot, remove it.
In order to avoid personal in-
juries, do not touch any high
voltage wirings and their con-
nectors, and high voltage
parts (inverter unit, hybrid ve-
hicle battery, etc.).
If some exposed electric
wires are protruding inside or
outside of your vehicle, an
electric shock may occur.
Never touch the electric
wires.
If fluid leaks or gets in some
parts of the vehicle, never
touch it because it may be
electrolyte (strong alkali) from
the hybrid vehicle battery. If
it gets into your skin or eyes,
wash off immediately with a
large amount of water, if pos-
sible, boric acid solution, and
get immediate medical atten-
tion in order to help avoid
serious injury.
If a vehicle fire occurs, extin-
guish it using a fire extin-
guisher for the exclusive use
on electric fires. Or, use a
large amount of water to pre-
vent flammable gas from be-
ing generated from the batter-
ies.