2001 TOYOTA PRIUS Service Repair Manual

BO3QO±01
H13682
H13683
Clip
H136842 Clips
H136857 Clips
± BODYREAR DOOR
BO±19
2001 PRIUS (RM778U)
DISASSEMBLY
1. REMOVE INSIDE HANDLE BEZEL
(a) Using a screwdriver, open the screw cap.
HINT:
Tape the screwdriver tip before use.
(b) Remove the screw.
(c) Using a screwdriver, remove the inside handle bezel as
shown in the illustration.
HINT:
Tape the screwdriver tip before use.
2. REMOVE POWER WINDOW SWITCH
(a) Remove the screw.
(b) Using a screwdriver, remove the power window switch.
HINT:
Tape the screwdriver tip before use.
(c) Disconnect the connector.
3. REMOVE REAR DOOR LOWER BRACKET GARNISH
Using a screwdriver, remove the rear door lower bracket gar-
nish.
HINT:
Tape the screwdriver tip before use.
4. REMOVE DOOR TRIM
(a) Remove the clip.
(b) Insert a screwdriver between the door panel and door trim
to pry the trim out.
NOTICE:
Be careful not to damage the door panel and trim.
HINT:
Tape the screwdriver tip before use.
(c) Pull the trim upward to remove it.

H15391
H15429
H15430Protective Tape
H15427
H15428
BO±20
± BODYREAR DOOR
2001 PRIUS (RM778U)
5. REMOVE INSIDE HANDLE
Remove the screw and inside handle, disconnect the 2 cables
from the inside handle as shown in the illustration.
6. REMOVE DOOR TRIM BRACKET NO. 1
Remove the 2 screws and door trim bracket, then remove the
2 grommets.
7. REMOVE SERVICE HOLE COVER
Remove the service hole cover.
NOTICE:
Do not tear the cover.
HINT:
At the time of reassembly, please refer to the following item.
Bring out the 2 control cables and wire harness through the ser-
vice hole cover.
8. REMOVE DOOR BELT MOULDING
Using a scraper, remove the door belt moulding.
HINT:
Tape the scraper tip before use.
9. REMOVE DOOR LOCK LINK SILENCER
10. REMOVE DOOR GLASS RUN
11. REMOVE WEATHERSTRIP
12. REMOVE DIVISION BAR
(a) Remove the 2 bolts and screw.
(b) Pull the division bar forward.
(c) Rotate the division bar 90° and pull it upward as shown
in the illustration.
13. REMOVE QUARTER WINDOW GLASS
(a) Remove the quarter window glass with the weatherstrip.
(b) Remove the weatherstrip from the quarter window glass.

H13687
H15431
H15432
H15433
± BODYREAR DOOR
BO±21
2001 PRIUS (RM778U)
14. REMOVE INSIDE PANEL PLATE
Remove the 3 screws and inside panel plate.
15. REMOVE INSIDE PANEL REINFORCEMENT
Remove the 4 screws and inside panel plate.
16. REMOVE DOOR GLASS
(a) Side out the door glass from the window regulator.
NOTICE:
Be careful not to drop the door glass.
(b) Pull the door glass upward to remove it.
17. REMOVE WINDOW REGULATOR
Disconnect the connector, then remove the 4 bolts and window
regulator.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
HINT:
Remove the regulator through the service hole.
HINT:
At the time of reassembly, please refer to the following item.
Apply MP grease to the window regulator.
18. REMOVE DOOR LOCK
(a) Remove the child protection cover.
(b) Disconnect the connector.
(c) Using a screwdriver, remove the door lock link guide and
clamp.
HINT:
Tape the screwdriver tip before use.
(d) Remove the 3 screws.
Torque: 4.9 N´m (50 kgf´cm, 43 in.´lbf)
HINT:
At the time of reassembly, please refer to the following item.
Apply adhesive to the 3 screws.
Part No. 08833±00070, THREE BOND 1324 or equiva-
lent
(e) Remove the bolts.
(f) Remove the door lock through the service hole.

H15434
BO±22
± BODYREAR DOOR
2001 PRIUS (RM778U)
HINT:
At the time of reassembly, please refer to the following item.
Apply MP grease to the sliding and rotating parts of the door
lock.
19. REMOVE OUTSIDE HANDLE
(a) Remove the 2 bolts.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
(b) Remove the outside handle and key cylinder.

BO3QS±01
H15480
H15418
H15419
H15420
BO±26
± BODYLUGGAGE COMPARTMENT DOOR AND HINGE
2001 PRIUS (RM778U)
REMOVAL
1. REMOVE LUGGAGE COMPARTMENT DOOR TRIM
Remove the 10 clips and luggage compartment door trim.
2. REMOVE LUGGAGE COMPARTMENT DOOR LOCK
(a) Remove the 2 bolts and luggage compartment door lock.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
(b) Disconnect the link and cable from the lock.
3. REMOVE LUGGAGE COMPARTMENT DOOR OUTER
GARNISH
(a) Remove the 4 nuts.
(b) Remove the luggage compartment door outer garnish
and key cylinder.
4. REMOVE LICENCE PLATE LIGHT
(a) Disconnect the connector.
(b) Remove the licence plate light as shown in the illustration.
(c) Employ the same manner described above to the other
side.
(d) Using a clip remover, remove the clamps.
5. REMOVE LUGGAGE COMPARTMENT DOOR
Remove the 4 bolts luggage compartment door.
Torque: 8.3 N´m (85 kgf´cm, 74 in.´lbf)
6. REMOVE LUGGAGE REAR FLOOR FINISH PLATE
(a) Using a clip remover, remove the 4 clips.
(b) Remove the rear floor finish plate.
7. REMOVE LUGGAGE COMPARTMENT DOOR WEATH-
ERSTRIP