2001 TOYOTA PRIUS Service Repair Manual

I17968
CO±18
± COOLINGRADIATOR AND CONDENSER MODULE
2001 PRIUS (RM778U)
8. REMOVE RADIATOR & CONDENSER MODULE
(a) Push the radiator & condenser module toward engine.
(b) Pull up the radiator until the lower radiator support is re-
moved.
(c) Pull it downward to remove it.

CO149±01
I17963
I17964
CO±22
± COOLINGELECTRIC COOLING FAN
2001 PRIUS (RM778U)
REMOVAL
1. DISCHARGE REFRIGERANT FROM REFRIGERATION
SYSTEM
HINT:
At the time of installation, please refer to the following item.
Evacuate air from refrigeration system.
Charge system with refrigerant and inspect for leakage of refrig-
erant.
Specified amount: 500 ± 50 g (17.64 ± 1.76 oz.)
2. DRAIN ENGINE COOLANT FROM RADIATOR
HINT:
It is not necessary to drain out all coolant.
3. REMOVE BRACKETS
(a) Remove the water hose from fan shroud.
(b) Remove the 5 bolts and 2 brackets.
4. REMOVE SUCTION AND DISCHARGE HOSES
(a) Remove the 2 bolts and disconnect the both hoses.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
HINT:
At the time of installation, please refer to the following item.
Lubricate 2 new O±rings with compressor oil and install them
to the tubes.
(b) Loosen the 2 nuts and remove the both hoses.
Torque:
Suction hose 32 N´m (330 kgf´cm, 24 ft´lbf)
Discharge hose 22 N´m (225 kgf´cm, 16 ft´lbf)
HINT:
At the time of installation, please refer to the following item.
Lubricate 2 new O±rings with compressor oil and install them
to the tubes.

I17965
I17967
I17956
± COOLINGELECTRIC COOLING FAN
CO±23
2001 PRIUS (RM778U)
5. DISCONNECT RADIATOR HOSES FROM RADIATOR
AND CONDENSER MODULE
(a) Using pliers, grip the claw of the hose clip and slide the
clip along the hose.
(b) Disconnect the radiator hoses.
6. REMOVE ELECTRIC COOLING FAN ASSEMBLY
(a) Disconnect the 2 connectors.
(b) Remove the 2 bolts.
(c) Pull up the electric cooling fan assembly until the it is re-
moved from the radiator and condenser module.
(d) Pull it downward to remove it.

I18027
No. 1 Cooling
Fan Relay
CO14D±01
B03548No ContinuityContinuity 12 Ohmmeter
5Ohmmeter
3
B03549
Ohmmeter
Continuity1
32
5
Battery
I18027
No. 2 Cooling
Fan Relay
B03550
Continuity
Ohmmeter
No Continuity Continuity4
1
32
Ohmmeter
5
Ohmmeter
± COOLINGCOOLING FAN RELAY
CO±27
1305 Author: Date:
2001 PRIUS (RM778U)
COOLING FAN RELAY
INSPECTION
1. INSPECT NO. 1 COOLING FAN RELAY
(a) Remove the relay box cover.
(b) Remove the No. 1 cooling fan relay. (Marking: FAN NO.
1)
(c) Inspect the No. 1 cooling fan relay continuity.
(1) Using an ohmmeter, check that continuity exists be-
tween terminals 1 and 2.
If no continuity exists, replace the relay.
(2) Check that no continuity exists between terminals
3 and 5.
If continuity exists, replace the relay.
(d) Inspect the No. 1 cooling fan relay operation.
(1) Apply battery voltage across terminals 1 and 2.
(2) Using an ohmmeter, check that continuity exists be-
tween terminals 3 and 5.
If no continuity exists, replace the relay.
(e) Reinstall the No. 1 cooling fan relay.
(f) Reinstall the relay box cover.
2. INSPECT NO. 2 COOLING FAN RELAY
(a) Remove the relay box cover.
(b) Remove the No. 2 cooling fan relay. (Marking: FAN NO.
2)
(c) Inspect the No. 2 cooling fan relay continuity.
(1) Using an ohmmeter, check that continuity exists be-
tween terminals 1 and 2.
If no continuity exists, replace the relay.
(2) Check that continuity exists between terminals 3
and 4.
If no continuity exists, replace the relay.
(3) Check that no continuity exists between terminals
3 and 5.
If continuity exists, replace the relay.

B03551
Ohmmeter
ContinuityOhmmeter
No Continuity4
1
32
5Battery
I18027
No. 3 Cooling
Fan Relay
B03548
Ohmmeter
No ContinuityOhmmeter
Continuity
5
3 12
B03549
Ohmmeter
Continuity5
3 12
Battery CO±28
± COOLINGCOOLING FAN RELAY
1306 Author: Date:
2001 PRIUS (RM778U)
(d) Inspect the No. 2 cooling fan relay operation.
(1) Apply battery voltage across terminals 1 and 2.
(2) Using an ohmmeter, check that no continuity exists
between terminals 3 and 4.
If continuity exists, replace the relay.
(3) Using an ohmmeter, check that continuity exists be-
tween terminals 3 and 5.
If no continuity exists, replace the relay.
(e) Reinstall the No. 2 cooling fan relay.
(f) Reinstall the relay box cover.
3. INSPECT NO. 3 COOLING FAN RELAY
(a) Remove the relay box cover.
(b) Remove the No. 3 cooling fan relay. (Marking: Fan NO. 3)
(c) Inspect the No. 3 cooling fan relay continuity.
(1) Using an ohmmeter, check that continuity exists be-
tween terminals 1 and 2.
If no continuity exists, replace the relay.
(2) Check that no continuity exists between terminals
3 and 5.
If continuity exists, replace the relay.
(d) Inspect the No. 3 cooling fan relay operation.
(1) Apply battery voltage across terminals 1 and 2.
(2) Using an ohmmeter, check that continuity exists be-
tween terminals 3 and 5.
If no continuity exists, replace the relay.
(e) Reinstall the No. 3 cooling fan relay.
(f) Reinstall the relay box cover.