2001 TOYOTA PRIUS battery

IN05Y±22
± INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN±29
29 Author: Date:
2001 PRIUS (RM778U)
HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
GENERAL INFORMATION
A large number of ECU controlled systems are used in the PRIUS. In general, the ECU controlled system
is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to
troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshooting of
these systems is not complex. If you have adequate understanding of the system and a basic knowledge
of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the problem. This
manual is designed through emphasis of the above standpoint to help service technicians perform accurate
and effective troubleshooting, and is compiled for the following major ECU controlled systems:
The troubleshooting procedure and how to make use of it are described on the following pages.
SystemPage
6. EngineDI±1
7. Hybrid Vehicle Control SystemDI±174
8. HV Battery Control SystemDI±312
9. Anti±Lock Brake System With EBD & RBSDI±351
10.Electric Motor Power SteeringDI±452
11. Supplemental Restraint SystemDI±495
12.Cruise Control SystemDI±640
13.Combination Meter SystemDI±662
14.Body Control SystemDI±678
15.Driver Door Control SystemDI±730
16.Multiplex Communication SystemDI±750
17.Navigation SystemDI±789
18.Air Conditioning SystemDI±864
FOR USING OBD II SCAN TOOL OR TOYOTA HAND±HELD TESTER

Before using the scan tool or tester, the scan tool's instruction book or tester's operator manual should
be read thoroughly.

If the scan tool or tester cannot communicate with ECU controlled systems when you have connected
the cable of the scan tool or tester to DLC3, turned the ignition switch ON and operated the scan tool,
there is a problem on the vehicle side or tool side.
(1) If communication is normal when the tool is connected to another vehicle, inspect the diagnosis
data link line (Bus
line) or ECU power circuit of the vehicle.
(2) If communication is still not possible when the tool is connected to another vehicle, the problem
is probably in the tool itself, so perform the Self Test procedures outline in the Tester Operator's
Manual.

IN±32± INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
2001 PRIUS (RM778U)
2. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK
The diagnostic system in the PRIUS fulfills various functions. The first function is the Diagnostic Trouble
Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory
at the time of occurrence, to be output by the technician during troubleshooting. Another function is the Input
Signal Check which checks if the signals from various switches are sent to the ECU correctly.
By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can
be performed effectively. Diagnostic functions are incorporated in the following systems in the PRIUS.
SystemDiagnostic Trouble
Code CheckInput Signal Check
(Sensor Check)Diagnostic Test
Mode (Active Test)
Engine (with Check
Mode)
Hybrid Vehicle Control System
HV Battery Control System (with Check
Mode)
Anti±Lock Brake System With EBD & RBS
Electric Motor Power Steering
Supplemental Restraint System
Cruise Control System
Multiplex Communication System
Navigation System
Air Conditioning System

IN04Q±11
IN±46
± INTRODUCTIONTERMS
46 Author: Date:
2001 PRIUS (RM778U)
TERMS
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti±Lock Brake System
ACAlternating Current
ACCAccessory
ACISAcoustic Control Induction System
ACSDAutomatic Cold Start Device
A.D.D.Automatic Disconnecting Differential
A/FAir±Fuel Ratio
AHCActive Height Control Suspension
ALRAutomatic Locking Retractor
ALTAlternator
AMPAmplifier
ANTAntenna
APPROX.Approximately
A/TAutomatic Transmission (Transaxle)
AT FAutomatic Transmission Fluid
AUTOAutomatic
AUXAuxiliary
AV GAverage
AV SAdaptive Variable Suspension
BABrake Assist
BACSBoost Altitude Compensation System
BATBattery
BDCBottom Dead Center
B/LBi±Level
B/SBore±Stroke Ratio
BTDCBefore Top Dead Center
BVSVBimetallic Vacuum Switching Valve
Calif.California
CBCircuit Breaker
CCoCatalytic Converter For Oxidation
CDCompact Disc
CFCornering Force
CGCenter Of Gravity
CHChannel
COMB.Combination
CPECoupe
CPSCombustion Pressure Sensor
CPUCentral Processing Unit
CRSChild Restraint System
CTRCenter
C/VCheck Valve
CVControl Valve

IN0CI±02
± INTRODUCTIONTERMS
IN±51
2001 PRIUS (RM778U)
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE±J1930 terms and abbreviations used in this manual in compliance with SAE rec-
ommendations, as well as their TOYOTA equivalents.
SAE
ABBREVIATIONSSAE TERMSTOYOTA TERMS
( )±±ABBREVIATIONS
A/CAir ConditioningAir Conditioner
ACLAir CleanerAir Cleaner, A/CL
AIRSecondary Air InjectionAir Injection (AI)
APAccelerator Pedal±
B+Battery Positive Voltage+B, Battery Voltage
BAROBarometric PressureHAC
CACCharge Air CoolerIntercooler
CARBCarburetorCarburetor
CFIContinuous Fuel Injection±
CKPCrankshaft PositionCrank Angle
CLClosed LoopClosed Loop
CMPCamshaft PositionCam Angle
CPPClutch Pedal Position±
CTOXContinuous Trap Oxidizer±
CTPClosed Throttle PositionLL ON, Idle ON
DFIDirect Fuel Injection (Diesel)Direct Injection (DI)
DIDistributor Ignition±
DLC1
DLC2
DLC3Data Link Connector 1
Data Link Connector 2
Data Link Connector 31: Check Connector
2: Total Diagnosis Comunication Link (TDCL)
3: OBD II Diagnostic Connector
DTCDiagnostic Trouble CodeDiagnostic Code
DTMDiagnostic Test Mode±
ECLEngine Control Level±
ECMEngine Control ModuleEngine ECU (Electronic Control Unit)
ECTEngine Coolant TemperatureCoolant Temperature, Water Temperature (THW)
EEPROMElectrically Erasable Programmable Read Only Memory
Electrically Erasable Programmable Read Only Memory
(EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFEEarly Fuel EvaporationCold Mixture Heater (CMH), Heat Control Valve (HCV)
EGRExhaust Gas RecirculationExhaust Gas Recirculation (EGR)
EIElectronic IgnitionTOYOTA Distributorless Ignition (TDI)
EMEngine ModificationEngine Modification (EM)
EPROMErasable Programmable Read Only MemoryProgrammable Read Only Memory (PROM)
EVAPEvaporative EmissionEvaporative Emission Control (EVAP)
FCFan Control±
FEEPROMFlash Electrically Erasable Programmable
Read Only Memory±
FEPROMFlash Erasable Programmable Read Only Memory±
FFFlexible Fuel±
FPFuel PumpFuel Pump
GENGeneratorAlternator
GNDGroundGround (GND)

PP26E±02
PP±50
± PREPARATIONBODY ELECTRICAL
2001 PRIUS (RM778U)
EQUIPMENT
Voltmeter
Ammeter
Ohmmeter
Test lead
SyphonBrake fluid level warning switch
Bulb (3.4W)Fuel sender gauge, Fuel level warning switch
Dry cell batteryWireless door lock transmitter
Torque wrench
Masking tapeRear window defogger wire
Tin foilRear window defogger wire

SS1HH±02
SS±20
± SERVICE SPECIFICATIONSHYBRID VEHICLE CONTROL
142 Author: Date:
2001 PRIUS (RM778U)
HYBRID VEHICLE CONTROL
SERVICE DATA
HV battery therm-
istor
Resistance at 25 °C (77 °F)
1 e 2
3 e 4
5 e 6
7 e 8
9 e 10
9 ± 11 kW
9 ± 11 kW
9 ± 11 kW
9 ± 11 kW
9 ± 11 kW
ConverterOutput current100 A or less
Water temperature
switchat 48 °C (118.4 °F) or less
at more than 55 °C (131 °F)No continuity
Continuity
Service plugService plug lever Close
Stand upContinuity
No continuity
Auxiliary batteryVoltage at 20 °C (68 °F)12.5 ± 12.9 V

SS1HI±01
± SERVICE SPECIFICATIONSHYBRID VEHICLE CONTROL
SS±21
2001 PRIUS (RM778U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Battery module x Battery carrier4.04035 in.´lbf
Battery clamp bolt x Battery carrier2323016
RH battery bracket x Battery carrier2323016
Battery ECU x Battery carrier3.33329 in.´lbf
Busber module x Battery module6.06153 in.´lbf
Power cable x SMR5.05044 in.´lbf
Service plug assembly x Battery carrier6.06153 in.´lbf
Battery cover x Battery carrier Bolt A
(See page HV±9) Bolt B
Bolt C
Screw18
8.0
7.0
6.0185
80
70
6113
71 in.´lbf
62 in.´lbf
53 in.´lbf
Battery bracket1818513
HV battery x Body1818513
Battery carrier catch bracket x Battery bracket8.08071 in.´lbf
Bracket x Converter & Inverter assembly2525518
Upper inverter cover x Converter & inverter assembly2.52522 in.´lbf
Inverter reservoir tank x Converter & inverter assembly8.08271 in.´lbf
Converter & inverter assembly x Body2121415
Ground cable x Radiator upper support8.08271 in.´lbf
Power cable for MG1 x Converter & inverter assembly7.07162 in.´lbf
Connector cover x Converter & inverter assembly2020415
Power cable for MG2 x Converter & inverter assembly Bolt A
(See page HV±22) Bolt B19.5
8.0199
8214
71 in.´lbf
Inverter terminal cover x Converter & inverter assembly8.08271 in.´lbf
HV water pump x Body7.07062 in.´lbf
Inverter radiator x Body8.08271 in.´lbf
Water temperature switch x Inverter radiator7.47565 in.´lbf
Blower assembly x Body5.05144 in.´lbf
Lower quarter ventilator duct x Body4.04135 in.´lbf
Inner ventilator duct x Body4.04135 in.´lbf
HV ECU x Body6.06053 in.´lbf

SS02V±05
± SERVICE SPECIFICATIONSBODY ELECTRICAL
SS±33
155 Author: Date:
2001 PRIUS (RM778U)
BODY ELECTRICAL
SERVICE DATA
DAYTIME RUNNING RELAY (MAIN) (Wire harness side)
12 ± Ground (Ignition switch OFF)No voltage
12 ± Ground (Ignition switch ON)Battery voltage
9 ± Ground (Engine Running)Battery voltage
3 ± Ground (Constant)Battery voltage
6 ± Ground (Constant)Battery voltage
SPEEDOMETER (ON±VEHICLE)
Standard indication (mph)Allowable range (mph)
2018 ± 22
4038 ± 42
6059 ± 63
8079 ± 83
10099 ± 104
120119 ± 125
Standard indication (km/h)Allowable range (km/h)
2018 ± 22
4038 ± 42
6058 ± 62
8078 ± 82
10097 ± 103
120117 ± 123
140137 ± 143
160157 ± 163
FUEL SENDER GAUGE
Float position mm (in.)Resistance (W)
F: Approx. 25.2 (0.99)Approx. 430
1/2: Approx. 92.6 (3.65)Approx. 1000 ± 2000
E: Approx. 169 (6.65)Approx. 5000
DEFOGER SWITCH (Wire harness side)
1 ± Ground (Ignition switch LOCK or ACC)No voltage
1 ± Ground (Ignition switch ON)Battery voltage
8 ± Ground (Constant)Battery voltage
WIRELESSS DOOR LOCK CONTROL RECEIVER (Wire harness side)
5 ± Ground (Constant)Battery voltage
POWER MIRROR SWITCH (Wire harness side)
8 ± Ground (Ignition switch LOCK)No voltage
8 ± Ground (Ignition switch ACC or ON)Battery voltage
RADIO RECEIVER (Wire harness side)
3 ± Ground (Ignition switch LOCK)No voltage
3 ± Ground (Ignition switch ACC or ON)Battery voltage
4 ± Ground (Constant)Battery voltage
CENTER CLUSTER SWITCH (Wire harness side)
1 ± Ground (Ignition switch ACC or ON)Battery voltage