engine TOYOTA PRIUS 2006 2.G Workshop Manual

399
DOITYOURSELF MAINTENANCE
Engine and Chassis
Checking the engine oil level400
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Checking the coolant level 402
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Checking the radiator and condenser 404
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Checking brake fluid 404
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Checking tire inflation pressure 405
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Checking and replacing tires 407
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Rotating tires 409
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Installing snow tires and chains 410
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Replacing wheels 411
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Aluminum wheel precautions 412
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SECTION 8– 2

400
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 level ground. After turning
off the hybrid system, wait a few min-
utes 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 as follows:
1.5 L (1.6 qt., 1.3 Imp.qt.)
For the engine oil capacity, see “Service
specifications” on page 427.
When the level reaches within the correct
range, install the filler cap hand− tight.
Checking the engine oil level

401
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.
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:
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.

402
Oil identification mark
The ILSAC (International Lubricant Stan-
dardization and Approval Committee) Certi-
fication Mark is added to some oil con-
tainers to help you select the oil you
should use.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

404
If either of the above parts is 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 level is low, take your vehicle to
a Toyota dealer as soon as possible. Do
not drive if the red brake system warn-
ing light is on. Call a Toyota dealer for
assistance.
If the fluid level goes down soon after your
vehicle is serviced, it may indicate a seri-
ous mechanical problem.
CAUTION
Brake fluid can harm your hands or
eyes. If fluid gets on your hands or
in your eyes, flush the affected area
with clean water immediately. If you
still feel uncomfortable with your
hands or eyes, go to the doctor.
NOTICE
If you spill some of the fluid, be sure
to wipe it off to prevent it from dam-
aging the parts or paintwork.
Checking the radiator and
condenser

418
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.
The stop lights and high mounted stoplight
consist of a number of LEDs. If any of
LEDs burn out, take your vehicle to your
Toyota dealer to have the light replaced.
If two or more LEDs in a stop light burn
out, your vehicle may not conform to local
laws (SAE).
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 highintensity dis-
charge headlight’s high voltage
socket when the headlights are
turned on. An extremely high volt-
age of 20,000V will be discharged
and could result in serious injury
or death by electric shock.
Do not attempt to take apart or re-
pair the headlight bulbs, connec-
tors, power supply circuits, or re-
lated components. Doing so could
result in electric shock and serious
injury or death. Call your Toyota
dealer for headlight repair or servic-
ing, including replacement of bulbs
and bulb disposal.
NOTICE
Only use a bulb of the listed type.
Adding washer fluidReplacing light bulbs—

425
SPECIFICATIONS
Dimensions and weight426
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Electric motor 426
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Enginee 426
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Fuel 427
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Hybrid battery 427
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Service specifications 427
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Tires 429
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Fuses 430
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SECTION 9

426
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.) 365 (810)
*: 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: 1.5 L 4
−cylinder (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

427
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 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

428
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: 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.