2001 TOYOTA PRIUS light

A01190
A10470
Block
Side:Cap
Side:
ABCD
A10459
1
24
35
6
7
8
9
10
± ENGINE MECHANICALCYLINDER BLOCK
EM±79
2001 PRIUS (RM778U)
3. Supply parts:
INSTALL MAIN BEARINGS
HINT:
Upper bearings have an oil groove and oil holes; Lower bear-
ings do not.
(a) Align the bearing claw with the claw groove of the cylinder
block, and push in the 5 upper bearings.
NOTICE:
Install the bearing with the oil hole in the cylinder block.
(b) Align the bearing claw with the claw grove of the main
bearing cap, and push in the 5 lower bearings.
4. Manufacture parts:
INSTALL MAIN BEARINGS
HINT:
Upper bearings have an oil groove and oil holes; Lower bear-
ings do not.
Measure the clearance on both sides of the bearing and install
it so that the difference between measured values will be within
the specified bellow.
Specified clearance:
A ± B = 0.8 mm (0.032 in.)
C ± D = 0.4 mm (0.016 in.)
5. PLACE CRANKSHAFT ON CYLINDER BLOCK
6. INSTALL BEARING CAPS
(a) Install the 5 bearing caps.
HINT:
Each bearing cap has a number and front mark.
(b) Apply a light coat of engine oil on the threads and under
the head of the bearing cap bolts.

A01205
A10456
EM±80
± ENGINE MECHANICALCYLINDER BLOCK
2001 PRIUS (RM778U)
(c) Install and uniformly tighten the 10 bolts of the bearing
cap is several passes, in the sequence shown.
Torque:
1ST 22 N´m (220 kgf´cm, 16 ft´lbf)
2ND Turn 90 °
(d) Check that the crankshaft turns smoothly.
7. CHECK CRANKSHAFT THRUST CLEARANCE
(See page EM±64)
8. INSTALL PISTON AND CONNECTING ROD
ASSEMBLES
Using a piston ring compressor, push the correctly numbered
piston and connecting rod assemblies into each cylinder with
the front mark of the piston facing forward.
9. PLACE CONNECTING ROD CAP ON CONNECTING
ROD
(a) Match the numbered connecting rod cap with the con-
necting rod.
(b) Align the pin dowels of the connecting rod cap with the
pins of the connecting rod, and install the connecting rod.
(c) Check that the protrusion of the connecting rod cap is fac-
ing in the correct direction.
10. INSTALL CONNECTING ROD CAP BOLTS
HINT:

The connecting rod cap bolts are tightened in 2 progres-
sive steps (steps (b) and (d)).

If any of the connecting rod cap bolts is broken or de-
formed, replace it.
(a) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(b) Install and alternately tighten the 2 connecting rod cap
bolts in several passes.
Torque:
1ST 15 N´m (150 kgf´cm, 11 ft´lbf)
2ND Turn 90 °
If any of the connecting rod cap bolts does not meet the torque
specification, replace the connecting rod cap bolts.
11. CHECK CONNECTING ROD THRUST CLEARANCE
(See page EM±64)

A10464
Seal Width 2 ± 3 mm
A11271
1
25
6
34
78910
11
12151314
BCAB
± ENGINE MECHANICALCYLINDER BLOCK
EM±81
2001 PRIUS (RM778U)
12. INSTALL OIL PAN NO. 1
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surface of the oil pan No.
1 and cylinder block.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing grooves.

Thoroughly clean all components to remove all the
loose material.

Using a non±residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the oil pan No. 1 as shown in the
illustration.
Seal packing:
Part No. 08826±00080 or equivalent

Install a nozzle that has been cut to a 2 ± 3 mm (0.08
± 0.12 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.

Parts must be assembled within 3 minutes of ap-
plication. Otherwise the material must be remove d
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install new O±rings to the cylinder block.
(d) Using a plastic±faced hammer, lightly tap the oil pan No.
1 to ensure a proper fit.
(e) Install and uniformly tighten the 13 bolts, in several
passes, in the sequence shown.
Torque: 24 N´m (245 kgf´cm, 18 ft´lbf)
HINT:
Each bolt length in indicated in the illustration.
A: 49 mm (1.929 in.)
B: 88 mm (3.465 in.)
C: 144 mm (5.669 in.)
13. INSTALL REAR CRANKSHAFT OIL SEAL
(See page EM±77)
HINT:
Wipe seal packing away from the contact surface of the cylinder
block assembly and oil seal.

B00417
SST
B11832
Fuel Pump
Connector
B00679
Vinyl Bag
SF±2
± SFISFI SYSTEM
1216 Author: Date:
2001 PRIUS (RM778U)
(b) When installing the battery, be especially careful not to in-
correctly connect the positive (+) and negative (±) cables.
(c) Do not permit parts to receive a severe impact during re-
moval or installation. Handle all SFI parts carefully, espe-
cially the ECM.
(d) Be careful during troubleshooting as there are numerous
transistor circuit, and even slight terminal contact can
cause further troubles.
(e) Do not open the ECM cover.
(f) When inspecting during rainy weather, take care to pre-
vent entry of water. Also, when washing the engine
compartment, prevent water from getting on the SFI parts
and wiring connectors.
(g) Parts should be replaced as an assembly.
(h) Care should be taken when pulling out and inserting wir-
ing connectors.
(1) Release the lock and pull out the connector, pulling
on the connectors.
(2) Fully insert the connector and check that it is locked.
(i) Use SST for inspection or test of the injector or its wiring
connector.
SST 09842±30080
7. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large
amount of gasoline will spill out, so observe these proce-
dures.
(1) Disconnect the fuel pump connector.
(2) Start the engine. After the engine has stopped on
its own, turn the ignition switch to LOCK.
(3) Disconnect the fuel tube from the fuel tank.
(4) Drain the fuel remained inside the fuel tube.
(5) Prevent the disconnected fuel tube from damaging
and mixing foreign objects by covering them with a
vinyl bag.

B00201
New Grommet
New O±Ring
SF1KQ±01
B00202
Turn
ConnectorPush
B11777
B11838
Rotate
Outward
B11777
SF±14
± SFIINJECTOR
2001 PRIUS (RM778U)
INSTALLATION
1. INSTALL INJECTORS AND DELIVERY PIPES
(a) Install the grommet to each injector.
(b) Apply a light coat of spindle oil or gasoline to new O±ring
and install them to each injector.
(c) Apply a light coat of spindle oil or gasoline on the place
where a delivery pipe touches on O±ring.
(d) While turning the injector clockwise and counterclock-
wise, push it to the delivery pipes. Install the 4 injectors.
(e) Position the injector connector outward.
(f) Place the 2 spacers in position on the cylinder head.
(g) Place the delivery pipe and fuel pipe together with the 4
injectors in position on the cylinder head.
(h) Temporarily install the 2 bolts holding the delivery pipe to
the cylinder head.
(i) Temporarily install the bolt holding the fuel pipe to the cyl-
inder head.
(j) Check that the injectors rotate smoothly.
HINT:
If injectors do not rotate smoothly, the probable cause is incor-
rect installation of O±ring. Replace the O±ring.
(k) Position the injector connector connector outward.
(l) Tighten the 2 bolts holding the delivery pipe to the cylinder
head.
Torque: 19 N´m (194 kgf´cm, 14 ft´lbf)
(m) Tighten the bolt holding the fuel pipe to the cylinder head.
Torque: 9.0 N´m (92 kgf´cm, 80 in.´lbf)

± HYBRID VEHICLE CONTROLCONVERTER AND INVERTER ASSEMBLY
HV±23
2001 PRIUS (RM778U)
5. OPERATION AFTER REPLACING CONVERTER & IN-
VERTER ASSEMBLY
Even if the master warning light is not lit, clear DTC using a
TOYOTA hand±held tester. When replacing a converter & in-
verter assembly of the vehicle in which no error occurs, also
clear DTC using a TOYOTA hand held tester.
HINT:
When a TOYOTA hand±held tester cannot be used, disconnect
the auxiliary battery for 1 min. or more and connect it again.
6. CHECKING AFTER REPLACING CONVERTER & IN-
VERTER ASSEMBLY
Depressing the accelerator pedal to a degree of 50 %, increase
the speed up to approx. 15 km/h 3 or 4 times to check that there
is no problem in the inverter operation.

± BRAKETROUBLESHOOTING
BR±3
1518 Author: Date:
2001 PRIUS (RM778U) Noise from brakes
1. Pad or lining (Cracked or distorted)
2. Installation bolt (Loose)
3. Disc or drum (Scored)
4. Pad support plate (Loose)
5. Sliding pin (Worn)
6. Pad or lining (Dirty)
7. Pad or lining (Glazed)
8. Tension or return spring (Faulty)
9. Anti±squeal shim (Damaged)
10.Shoe hold±down spring (Damaged)BR±23
BR±32
BR±26
BR±26
BR±32
BR±23
BR±26
BR±23
BR±32
BR±23
BR±32
BR±32
BR±23
BR±32
Brake warning light lights up*1
(Parking brake pedal released)
1. Brake fluid level
2. Hydraulic brake booster power supply system (Faulty)
BR±41
Brake warning light lights up and brake warning buzzer sounds*2Hydraulic brake booster power supply system (Faulty)BR±41
ABS warning light lights up*31. Anti±lock brake system (Faulty)
2. Hydraulic brake booster power supply system (Faulty)
BR±41
*1, *3: The light may stay on for about 60 seconds after the engine has been started. It is normal if it goes
out after a while.
*
2, *3: Depressing the brake pedal repeatedly may turn on the warning light and buzzer. It is normal if the
light goes out and the buzzer stops sounding after a few seconds.

RS0JO±06
± SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
RS±1
1600 Author: Date:
2001 PRIUS (RM778U)
SRS AIRBAG
PRECAUTION
CAUTION:

The PRIUS is equipped with SRS, which comprises a driver airbag, front passenger airbag and
side airbag. Failure to carry out service operations in the correct sequence could cause the SRS
to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a
mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when re-
quired. Before performing servicing (including removal or installation of parts, inspection or
replacement), be sure to read the following items carefully, then follow the correct procedures
described in the repair manual.

Work must be started 90 seconds after the ignition switch is turned to the ºLOCKº position and
the negative (±) terminal cable is disconnected from the battery.
(The SRS is equipped with a back±up power source so that if work is started within 90 seconds
from disconnecting the negative (±) terminal cable of the battery, the SRS may be deployed.)

Do not expose the steering wheel pad, front passenger airbag assembly, side airbag assembly,
airbag sensor assembly, front airbag sensor or side airbag sensor assembly directly to hot air
or flames.
NOTICE:

Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most impor-
tant source of information when troubleshooting. When troubleshooting the SRS, always in-
spect the DTCs before disconnecting the battery.

Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front
passenger airbag assembly, side airbag assembly, airbag sensor assembly, front airbag sen-
sor and side airbag sensor assembly should be inspected.
(See page RS±14, RS±28, RS±41, RS±53, RS±58 and RS±63)

Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.

Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.

Never disassemble and repair the steering wheel pad, front passenger airbag assembly, side
airbag assembly, airbag sensor assembly, front airbag sensor or side airbag sensor assembly
in order to reuse it.

If the steering wheel pad, front passenger airbag assembly, side airbag assembly, airbag sen-
sor assembly, front airbag sensor or side airbag sensor assembly has been dropped, or if there
are cracks, dents or other defects in the case, bracket or connector, replace it with new one.

Use a volt/ohmmeter with high impedance (10 kW/V minimum) for troubleshooting the system's
electrical circuits.

Information labels are attached to the periphery of the SRS components. Follow the instruc-
tions on the notices.

After work on the SRS is completed, perform the SRS warning light check (See page DI±497).

When the negative (±) terminal cable is disconnected from the battery, the memory of the clock
and audio system will be canceled. So before starting work, make a record of the contents mem-
orized in the audio memory system. When work is finished, reset the audio systems as they
were before and adjust the clock. To avoid erasing the memory in each memory system, never
use a back± up power supply from outside the vehicle.

If the vehicle is equipped with a mobile communication system, refer to the precaution in the
IN section.