2001 TOYOTA PRIUS airbag

MA048±01
S01303
Dust Cover
± MAINTENANCECHASSIS
MA±7
60 Author: Date:
2001 PRIUS (RM778U)
CHASSIS
INSPECTION
1. INSPECT STEERING LINKAGE
(a) Check the steering wheel freeplay. (See page SR±3)
(b) Check the steering linkage for looseness or damage.
Check that:

Tie rod ends do not have excessive play.

Dust seals and boots are not damaged.

Boot clamps are not loose.
2. INSPECT SRS AIRBAG (See page RS±2)
3. INSPECT STEERING GEAR HOUSING OIL
Check the steering gear housing for oil leakage.
4. INSPECT DRIVE SHAFT BOOTS
Check the drive shaft boots for clamp looseness, leakage or
damage.
5. INSPECT BALL JOINTS AND DUST COVERS
(a) Inspect the ball joints for excessive looseness.

Jack up the front of the vehicle and place wooden
blocks with a height of 180 ± 200 mm (7.09 ± 7.87
in.) under the front tires.

Lower the jack until there is about half a load on the
front coil spring. Place stands under the vehicle for
safety.

Check that the front wheels are pointing straight
ahead, and block them with chocks.

Using a lever, pry up the end of the lower arm, and
check the amount of play.
Maximum ball joint vertical play: 0 mm (0 in.)
If there is play, replace the ball joint.
(b) Check the dust cover for damage.
6. CHECK TRANSAXLE OIL (FLUID)
Visually check the transaxle for oil (fluid) leakage.
If leakage is found, check for the cause and repair.
7. REPLACE TRANSAXLE OIL (FLUID)
Replace the transaxle oil (See page HT±26).

PP0SY±02
± PREPARATIONSUPPLEMENTAL RESTRAINT SYSTEM
PP±45
106 Author: Date:
2001 PRIUS (RM778U)
SUPPLEMENTAL RESTRAINT SYSTEM
SST (Special Service Tools)
09082±00700SRS Airbag Deployment Tool
09082±00750Airbag Deployment Wire
Sub±harness No.3for Side Airbag Assembly
09082±00760Airbag Deployment Wire
Sub±harness No.4for Driver's and Front Passenger
Airbag Assembly
09843±18040Diagnosis Check Wire No.2

PP0T0±01
± PREPARATIONSUPPLEMENTAL RESTRAINT SYSTEM
PP±47
2001 PRIUS (RM778U)
EQUIPMENT
Torque wrench
Bolt: Length: 35 mm (1.38 in.) Pitch: 1.0 mm (0.039 in.)
Diam: 6.0 mm (0.236 in.)Airbag disposal
Tire Width: 185 mm (7.28 in.) Inner diam: 360 mm (14.17 in.)Airbag disposal
Tire with disc wheel Width: 185 mm (7.28 in.)
Inner diam: 360 mm (14.17 in.)Airbag disposal
Vinyl bagAirbag disposal

PP3B4±01
PP±52
± PREPARATIONBODY
11 3 Author: Date:
2001 PRIUS (RM778U)
BODY
SST (Special Service Tools)
09812±00010Door Hinge Set Bolt Wrench
09804±24010Luggage Compartment Door Torsion
Bar Tool
09082±00700SRS Airbag Deployment Tool
09082±00730Airbag Deployment Wire Sub±Harne
ss No.1
09082±00740Airbag Deployment Wire
Sub±harness No.2

SS1HM±01
± SERVICE SPECIFICATIONSBODY
SS±35
157 Author: Date:
2001 PRIUS (RM778U)
BODY
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
FRONT BUMPER±±±
Side marker x Bumper1.71715 in.´lbf
HOOD±±±
Hood x Hinge131309
Hood lock x Body8.38574 in.´lbf
FRONT DOOR±±±
Outside view mirror x Door7.88069 in.´lbf
Window regulator arm x Door4.95043 in.´lbf
Window regulator body x Door8.38574 in.´lbf
Door lock x Door Bolt:4.95043 in.´lbf
Door lock x Door Screw:4.95043 in.´lbf
Outside handle x Door5.45548 in.´lbf
Hinge x Body4344032 in.´lbf
Hinge x Door4344032 in.´lbf
Door lock striker x Body2323017 in.´lbf
REAR DOOR±±±
Window regulator x Door5.45548 in.´lbf
Door lock x Door4.95043 in.´lbf
Outside handle x Body5.45548 in.´lbf
Hinge x Body2526019
Hinge x Door3031022
Door lock striker x Body2323017
LUGGAGE COMPARTMENT DOOR AND HINGE±±±
Door lock x Door5.45548 in.´lbf
Hinge x Door8.38574 in.´lbf
Door lock striker x Body5.45548 in.´lbf
FRONT WIPER AND WASHER±±±
Wiper arm x Wiper link2627020
Wiper motor x Wiper link Bolt:5.45548 in.´lbf
Wiper motor x Wiper link Nut:1717513
Wiper link x Outer front cowl top panel7.47565 in.´lbf
Outer front cowl top panel x Body5.45548 in.´lbf
ROOF HEADLINING±±±
Inner rear view mirror x Body2.93026 in.´lbf
INSTRUMENT PANEL±±±
Front passenger airbag assembly x Reinforcement2020415
FRONT SEAT±±±
Seat cushion frame x Body3738027
Seatback assembly x Seat cushion frame4344032
REAR SEAT±±±
Seatback assembly x Body7.98170 in.´lbf

± DIAGNOSTICSHYBRID VEHICLE CONTROL SYSTEM
DI±189
2001 PRIUS (RM778U)
179Impossible to drive
180Impossible to drive
181Impossible to drive
182Impossible to drive
183Impossible to drive
184Impossible to drive
185Impossible to drive
186Impossible to drive
187Impossible to drive
188Limited driving
189Limited driving
190Limited driving
191Limited driving
192Limited driving
P3100193HV ECU MalfunctionLimited drivingP3100
194
HV ECU Malfunction
Limited driving
195Limited driving
196Limited driving
197Limited driving
198Normal driving
199Limited driving
200Limited driving
201Limited driving
202Limited driving
203Limited driving
271Normal driving
310Limited driving
392Impossible to drive
393Impossible to drive
204Limited driving
P3101205Engine System MalfunctionLimited drivingP3101
238
Engine System Malfunction
Limited driving
206Limited driving
P3105207Battery ECU Communication
Circuit MalfunctionLimited drivingP3105
208Circuit MalfunctionLimited driving
209Limited driving
210Limited driving
P3106211ECM Communication Circuit
MalfunctionLimited drivingP3106
212MalfunctionLimited driving
394Limited driving
213Normal driving
P3107214Airbag ECU Communication
Circuit MalfunctionNormal drivingP3107
215Circuit MalfunctionNormal driving
P3108216A/C Amplifier CommunicationNormal drivingP3108217
A/C Am lifier Communication
Circuit MalfunctionNormal driving

DI±198
± DIAGNOSTICSHYBRID VEHICLE CONTROL SYSTEM
2001 PRIUS (RM778U)P3107
(DI±242)
Airbag ECU Communication Cir-
cuit Malfunction
Wire Harness

Airbag Sensor Assembly
P3108
(DI±244)A/C Amplifier Communication
Circuit Malfunction
Wire Harness

A/C AmplifierX
P3109
(DI±245)Brake ECU Communication Cir-
cuit Malfunction
Wire Harness

Brake ECU
P3110
(DI±247)IGCT Relay Malfunction
Wire Harness

IGCT Relay
P3115
(DI±249)System Main Relay Malfunction

Wire Harness

System Main Relay

HV ECU

P3120
(DI±252)HV Transaxle Malfunction

HV Transaxle

Wire Harness

System Main Relay

P3125
(DI±266)Converter & Inverter Assembly
Malfunction
Converter & Inverter Assembly

Wire Harness
P3130
(DI±302)Inverter Cooling System Mal-
function

Inverter Water Pump

Wire Harness

IG2 Relay

Electric Cooling Fan System

P3135
(DI±305)Circuit Breaker Sensor Malfunc-
tion
Circuit Breaker Sensor

Wire Harness
P3140
(DI±307)Interlock Malfunction

Interlock Switch

Inverter Terminal Cover

Converter & Inverter Assembly

Wire Harness

P3145
(DI±310)Vehicle Speed Sensor Circuit
Malfunction
Wire HarnessX
*: : Hybrid system warning light lights up. X: Hybrid system warning light does not light up.

DI±202
± DIAGNOSTICSHYBRID VEHICLE CONTROL SYSTEM
2001 PRIUS (RM778U)DTC NO.
INF. CodeDetection ItemDetecting Condition
209
210When communication between ECM and HV ECU is abnormal 1 sec. after
ignition is turned ON
P3106211ECM Communication Circuit
Malfunction
ignition is turned ON
P3106
212MalfunctionInput of abnormal signal from ECM
394When ECM does not operate
213
P3107214Airbag ECU Communication
Circuit Malfunction
When communication between airbag ECU and HV ECU is abnormal 10
sec after ignition is turned ONP3107
215Circuit Malfunctionsec. after ignition is turned ON
P3108216A/C Amplifier CommunicationWh i ti f A/C lifi t HV ECU i b lP3108217
A/C Am lifier Communication
Circuit MalfunctionWhen communication from A/C amplifier to HV ECU is abnormal
218
219When communication between brake ECU and HV ECU is abnormal 1.5
P3109220Brake ECU Communication
Circuit Malfunction
When communication between brake ECU and HV ECU is abnormal 1.5
sec. after ignition is turned ONP3109
221Circuit Malfunctiong
222When abnormal data is received from brake ECU
P3110223IGCT RelayWhen IGCT relay is always closed
224SMR C t1 M lf tiOpen or +B short in system main relay No. 1 circuit
225SMR Cont1 MalfunctionShort in system main relay No. 1 circuit
226SMR C t2 M lf tiOpen or +B short in system main relay No. 2 circuit
227SMR Cont2 MalfunctionShort in system main relay No. 2 circuit
P3115228SMR C t3 M lf tiOpen or +B short in system main relay No. 3 circuitP3115
229SMR Cont3 MalfunctionShort in system main relay No. 3 circuit
231System main relay + terminal deposited
232Deposit of SMRSystem main relay ± terminal deposited
233
De osit of SMR
System main relay + & ± terminal deposited
234Small reduction of motor magnetism
235E B l M lf tiLarge reduction of motor magnetism
236Energy Balance MalfunctionSmall reduction of generator magnetism
237Large reduction of generator magnetism
239Shaft damaged
240HV T l M lf tiGenerator locked
P3120241HV Transaxle MalfunctionTorque limiter slidingP3120242Planetary gear locked
243Motor resolver inter±phase short
244
Mt R l Mlf ti
Motor resolver inter±phase short (When there is a history that the state of
malfunction continued during inverter fail safe mode)
245Motor Resolver MalfunctionOpen or short in motor resolver circuit
246Open or short in motor resolver circuit (When there is a history that the
state of malfunction continued during inverter fail safe mode)