2001 TOYOTA PRIUS engine

AC37K±01
I17981
I03838
SST
I03839
SST
Push
SSTPull
Release
Lever
± AIR CONDITIONINGAIR CONDITIONING UNIT
AC±25
2001 PRIUS (RM778U)
REMOVAL
1. REMOVE FRONT WIPER AND OUTER FRONT COWL
TOP PANEL (See page BO±32)
2. 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.)
3. DRAIN ENGINE COOLANT FROM RADIATOR
HINT:
It is not necessary to drain out all coolant.
4. DISCONNECT LIQUID TUBE AND SUCTION HOSE
(a) Using SST, remove the 2 piping clamps.
SST 09870±00015 (Suction tube)
09870±00025 (Liquid tube)
(1) Insert SST to piping clamp.
HINT:
Confirm the direction of the piping clamp claw and SST using
the illustration showing on the caution label.
(2) Push down SST and release the clamp lock.
NOTICE:
Be careful not to deform the tubes, when pushing SST.
(3) Pull SST slightly and push the release lever, then re-
move the piping clamp with SST.
(4) Remove the piping clamp from SST.
(b) Disconnect the both tubes.

AC36Q±01
I17953
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable partBracket Water Hose
Radiator
Upper
Support

O±RingRadiator
Reservoir
Hose Suction Hose
Radiator and
Condenser
Module
Discharge Hose
Liquid Tube Discharge
Tube
5.4 (55, 48 in.´lbf)
22 (225, 16)
5.4 (55, 48 in.´lbf)

O±Ring
10 (100, 7)

O±Ring

O±RingSuction Tube

O±Ring
Bracket
Radiator
Upper
Support
Radiator
Hose
Condenser FanConnector
RH Engine Under Cover
LH Engine Under Cover
Front Bumper
O±Ring
32 (330, 24)
Front Spoiler Cover
± AIR CONDITIONINGRADIATOR AND CONDENSER MODULE
AC±45
2001 PRIUS (RM778U)
COMPONENTS

AC36R±01
I17955
I17954
± AIR CONDITIONINGRADIATOR AND CONDENSER MODULE
AC±47
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 the coolant.
3. REMOVE CONDENSER FAN ASSEMBLY
(See Page AC±69)
4. REMOVE FRONT BUMPER (See Page BO±4)
5. REMOVE RADIATOR RESERVOIR HOSE
6. DISCONNECT DISCHARGE AND LIQUID TUBE
(a) Remove the 2 bolts and disconnect discharge and liquid
tube.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
NOTICE:
Cap open the fittings immediately to keep moisture or dirt
out of the system.
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) Remove the bolt.
(c) Disconnect the liquid tube and remove the bracket.
7. REMOVE RADIATOR UPPER SUPPORT
Remove the 2 bolts and 2 radiator upper supports.

I17968
AC±48
± AIR CONDITIONINGRADIATOR 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.

I18027
Heater Main Relay
Magnetic
Clutch
Relay
Cooling
Fan No. 3
Relay
Cooling
Fan No. 1
Relay
Cooling
Fan No. 2
Relay
AC36O±01
I18028Heater 2 Relay
Heater 1 Relay
Heater 3 Relay
Water
Pump
Relay
I18286
3
2
15 4
1 4
32
5
N23635
3
2
15
4
Z18060
13
2 5
5 2
3
1
± AIR CONDITIONINGRELAY
AC±65
1953 Author: Date:
2001 PRIUS (RM778U)
RELAY
INSPECTION
1. REMOVE RELAY
(a) Remove the relay from the engine room J/B.
(b) Remove the relay from the engine room R/B No. 3.
2. INSPECT HEATER MAIN RELAY CONTINUITY
ConditionTester connectionSpecified condition
Constant3 ± 5
2 ± 4Continuity
Apply B+ between
terminals 5 and 3.1 ± 2Continuity
If continuity is not as specified, replace the relay.
3. INSPECT COOLING FAN NO. 2 RELAY CONTINUITY
ConditionTester connectionSpecified condition
Constant1 ± 2
3 ± 4Continuity
Apply B+ between
terminals 1 and 2.3 ± 5Continuity
If continuity is not as specified, replace the relay.
4. INSPECT MAGNETIC CLUTCH, COOLING FAN NO. 1,
3, HEATER 1, 2, WATER PUMP RELAY CONTINUITY
ConditionTester connectionSpecified condition
Constant1 ± 2Continuity
Apply B+ between
terminals 1 and 2.3 ± 5Continuity
If continuity is not as specified, replace the relay.

AC36D±01
I17963
I17964
± AIR CONDITIONINGCONDENSER FAN
AC±69
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.