2001 TOYOTA PRIUS Service Repair Manual

FI1066
IN0CO±17
Z11554
Seal Lock Adhesive
IN±4
± INTRODUCTIONREPAIR INSTRUCTIONS
4 Author: Date:
2001 PRIUS (RM778U)
REPAIR INSTRUCTIONS
GENERAL INFORMATION
BASIC REPAIR HINT
(a) Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
(b) During disassembly, keep parts in the appropriate order
to facilitate reassembly.
(c) Installation and removal of battery terminal:
(1) Before performing electrical work, disconnect the
negative (±) terminal cable from the battery.
(2) If it is necessary to disconnect the battery for in-
spection or repair, first disconnect the negative (±)
terminal cable.
(3) When disconnecting the terminal cable, to prevent
damage to battery terminal, loosen the cable nut
and raise the cable straight up without twisting or
prying it.
(4) Clean the battery terminals and cable ends with a
clean shop rag. Do not scrape them with a file or oth-
er abrasive objects.
(5) Install the cable ends to the battery terminals after
loosening the nut, and tighten the nut after installa-
tion. Do not use a hammer to tap the cable ends
onto the terminals.
(6) Be sure the cover for the positive (+) terminal is
properly in place.
(d) Check hose and wiring connectors to make sure that they
are connected securely and correctly.
(e) Non±reusable parts
(1) Always replace cotter pins, gaskets, O±rings, oil
seals, etc. with new ones.
(2) Non±reusable parts are indicated in the component
illustrations by the ºº symbol.
(f) Precoated parts
Precoated parts are bolts, nuts, etc. that are coated with
a seal lock adhesive at the factory.
(1) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(2) When reusing precoated parts, clean off the old
adhesive and dry with compressed air. Then apply
the specified seal lock adhesive to the bolt, nut or
threads.

BE1367
Medium Current Fuse and High Current Fuse
Equal Amperage Rating
V00076
Abbreviation Part Name Symbol Illustration
FUSE
MEDIUM CURRENT FUSE
HIGH CURRENT FUSE
FUSIBLE LINK
CIRCUIT BREAKERFUSE
M±FUSE
H±FUSE
FL
CB
± INTRODUCTIONREPAIR INSTRUCTIONS
IN±5
5 Author: Date:
2001 PRIUS (RM778U)
(3) Precoated parts are indicated in the component il-
lustrations by the º
º symbol.
(g) When necessary, use a sealer on gaskets to prevent
leaks.
(h) Carefully observe all specifications for bolt tightening
torques. Always use a torque wrench.
(i) Use of special service tools (SST) and special service ma-
terials (SSM) may be required, depending on the nature
of the repair. Be sure to use SST and SSM where speci-
fied and follow the proper work procedure. A list of SST
and SSM can be found in Preparation section in this
manual.
(j) When replacing fuses, be sure the new fuse has the cor-
rect amperage rating. DO NOT exceed the rating or use
one with a lower rating.

IN0253
WRONG CORRECT
IN0252
WRONG CORRECT IN±6
± INTRODUCTIONREPAIR INSTRUCTIONS
6 Author: Date:
2001 PRIUS (RM778U)
(k) Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the prop-
er locations (See page IN±8).
Cancel the parking brake on the pedal place and
shift the transmission in N position.
When jacking up the front wheels of the vehicle at
first place stoppers behind the rear wheels.
When jacking up the rear wheels of the vehicle at
first place stoppers before the front wheels.
When either the front or rear wheels only should be
jacked up, set rigid racks and place stoppers in front
and behind the other wheels on the ground.
After the vehicle is jacked up, be sure to support it
on rigid racks . It is extremely dangerous to do any
work on a vehicle raised on a jack alone, even for
a small job that can be finished quickly.
(l) Observe the following precautions to avoid damage to the
following parts:
(1) Do not open the cover or case of the ECU unless
absolutely necessary. (If the IC terminals are
touched, the IC may be destroyed by static electric-
ity.)
(2) To disconnect vacuum hoses, pull off the end, not
the middle of the hose.
(3) To pull apart electrical connectors, pull on the con-
nector itself, not the wires.
(4) Be careful not to drop electrical components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not reused.
(5) When steam cleaning an engine, protect the elec-
tronic components, air filter and emission±related
components from water.
(6) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
(7) When checking continuity at the wire connector, in-
sert the tester probe carefully to prevent terminals
from bending.
(8) When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step±down
adapter for adjustment. Once the hose has been
stretched, it may leak air.

IN0002
Example
± INTRODUCTIONREPAIR INSTRUCTIONS
IN±7
7 Author: Date:
2001 PRIUS (RM778U)
(m) Installation and removal of vacuum hose:
(1) When disconnecting vacuum hoses, use tags to
identify how they should be reconnected to.
(2) After completing a job, double check that the vacu-
um hoses are properly connected. A label under the
hood shows the proper layout.
(n) Bleeding of hydraulic brake booster system:
When repairing the hydraulic brake booster or ABS,
bleeding the air out of the hydraulic brake booster (See
page BR±4).
(o) Unless otherwise stated, all resistance is measured at an
ambient temperature of 20°C (68°F). Because the resis-
tance may be outside specifications if measured at high
temperatures immediately after the vehicle has been run-
ning, measurement should be made when the engine has
cooled down.