2001 TOYOTA PRIUS torque

SS0LN±06
± SERVICE SPECIFICATIONSBRAKE
SS±29
2001 PRIUS (RM778U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
BRAKE PEDAL
Pedal bracket x Reinforcement1414310
Brake pedal x Pedal bracket3737527
PARKING BRAKE PEDAL
Pedal bracket x Reinforcement1414310
Pedal bracket x Body131309
Brake pedal x Pedal bracket3232724
BRAKE MASTER CYLINDER
Master cylinder x Pedal bracket131309
Master cylinder clevis lock nut2626519
HYDRAULIC BRAKE BOOSTER
Hydraulic brake booster assembly x Body1919414
Sub±bracket x Body1919414
Reservoir bracket x Body1818413
Reservoir x Bracket7.57766 in.´lbf
Accumulator x Booster pump5455036
Pressure switch assembly x Brake power supply bracket7.88069 in.´lbf
Booster pump x Brake booster pump bracket No. 27.88069 in.´lbf
Pressure switch assembly x Brake booster pump bracket No. 17.88069 in.´lbf
Connector bracket x Pressure switch assembly7.88069 in.´lbf
Pressure switch assembly x Brake booster pump bracket No. 27.88069 in.´lbf
FRONT BRAKE
Front disc brake caliper installation bolt3435025
Bleeder plug8.38574 in.´lbf
Front disc brake caliper x Flexible hose3031022
Front disc brake torque plate x Steering knuckle1071,09079
REAR BRAKE
Bleeder plug8.58775 in.´lbf
Rear drum brake wheel cylinder x Backing plate101007
BRAKE ACTUATOR
Brake actuator assembly x Body1919514
Brake actuator x Actuator bracket111208
SPEED SENSOR
Front speed sensor installation bolt8.08271 in.´lbf
Front speed sensor harness clamp bolt5.55649 in.´lbf
Rear speed sensor harness clamp bolt5.55649 in.´lbf
BRAKE LINE
Brake line union nut1515511

SS16Z±08
± SERVICE SPECIFICATIONSSTEERING
SS±31
2001 PRIUS (RM778U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
TILT STEERING COLUMN
Adjusting nut131309
No. 2 tilt lever lock bolt5.45548 in.´lbf
Tilt steering support lock nut9.510087 in.´lbf
Main shaft lower dust seal4.95043 in.´lbf
Column assembly set bolt and nut2526019
No. 2 intermediate shaft assembly x Main shaft assembly3536026
No. 2 intermediate shaft assembly x Intermediate extension3536026
Shift lock computer sub±assembly4.04035 in.´lbf
Steering wheel set nut5051037
Steering wheel pad set screw (Torx screw)8.89078 in.´lbf
POWER STEERING GEAR
Rack end x Steering rack62 (83)630 (850)46 (61)
Tie rod end lock nut5657041
PS gear assembly set bolt8385061
Stabilizer bar set bolt1919014
Suspension member137
1421,400
1,450101
105
Torque rod set nut1001,02074
EMPS bracket set bolt5.56052 in.´lbf
Lower suspension arm x Lower ball joint1421,450105
Stabilizer bar link set nut7476055
Tie rod end x Steering knuckle4950036
( ): For use without SST

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

± DIAGNOSTICSENGINE
DI±153
2001 PRIUS (RM778U)
DTC P3190 Poor Engine Power
DTC P3191 Engine dose not Start
CIRCUIT DESCRIPTION
From the HV ECU, the ECM receives data such as power output required for the engine (required output),
estimated torque produced by the engine (estimated torque), engine RPM of control target (target RPM),
whether the engine is in start mode or not. Then, based on the required output and target RPM, the ECM
calculates a target torque that is to be produced by the engine and compares it with the estimated torque.
If the estimated torque is very low compared with the target torque, or the engine start mode continues at
the engine RPM or for the duration calculated by water temperature, an abnormal condition is detected.
DTC No.DTC Detecting ConditionTrouble Area
P3190
Following condition (a) to (e) continues at a fixed engine RPM
or a fixed length of time:
(a) Communication with HV ECU is normal.
(b) Engine RPM is a fixed value or more.
(c) Engine star mode is not active.
(d) Target torque is a fixed value or more.
(e) Ratio of estimated torque against target torque is less than
20 %.

Air induction system

Throttle body

Fuel pressure

Engine

Air flow meter

Out of fuel
Wt t
P3191
Following condition (a) to (c) continues at a fixed engine RPM
or for a fixed length of time:
(a) Vommunication with HV ECU is normal.
(b) Engine RPM is a fixed value or more.
(c) Engine start mode is active.
Water temp. sensor

Crankshaft position sensor

Camshaft position sensor

ECM
WIRING DIAGRAM
Refer to DTC P1636 on page DI±146.
INSPECTION PROCEDURE
1 Are there any other codes begin output?
YES Go to relevant DTC chart.
NO
DI7T6±01

± DIAGNOSTICSHYBRID VEHICLE CONTROL SYSTEM
DI±193
2001 PRIUS (RM778U)
5. CHECK FOR INTERMITTENT PROBLEMS
(a) Perform a simulation test (See page IN±41).
In the simulation test, reproduce the driving condition at the trouble occurrence according to the cus-
tomer 's comments and freeze frame data recorded with DTC, such as an opening angle of the acceler-
ator pedal, SOC, engine coolant temperature, engine rpm, and MG/1MG2 rpm and torque.
(b) Check the connector and terminal (See page IN±41).
(c) Handle the connector (See page IN±41).
6. TOYOTA HAND±HELD TESTER DISPLAY ITEMS
TOYOTA Hand±held tester displayMeasurement Item
1 BEF LATST ORNumber of operation of 1 trip before last
1 BEF LATST TRPNumber of trips before last
2 BEF LATST ORNumber of operation 2 trips before last
2 BEF LATST TRPNumber of trips 2 before last
ABNML CON BR±HVCommunication malfunction between HV ECU and brake
ACC SENSOR MAINMain accelerator sensor
ACC SENSOR SUBSub accelerator sensor
ACC TENT TRBLETentative trouble of accelerator
ACC THROTTLEAccelerator throttle
ACCEL MODEHistory of acceleration and reduction
AIR CON REQUESTAir conditioner request
AUX. BATT LOWAuxiliary battery becomes week
AUX. BATT VVoltage of auxiliary battery
BATT HIGH TEMPTemperature of the battery is too high
BATT HIGH VOLTVoltage of the battery is too high
BATT LOW BOLTVoltage of the battery is low
BATT OVER LOADBattery is overloaded
BATT SAVE RQSTRequest to save the main battery
BATTERY FULLBattery full
BRAKE TORQBrake torque
CELL TEMP±MAXHighest temperature of all battery cells
CELL TEMP±MINLowest temperature of all battery cells
CHG RESTRICTIONCharge restriction
COOLANT TEMPWater temperature
CRUISE CONTROLCondition of the cruise control
DC/DC CONV STOPDC/DC converter stop signal
DC/DC CONV STOPFactors causing DC/DC converter to stop
DC/DC STOP FACTDC/DC converter has stopped at least once
DC/DC V UNSETDC/DC voltage is unsettled
DCHG RQST SOCDischarge request to adjust SOC
DISCHAG INHIBITBattery is inhibited to discharge

DI±194
± DIAGNOSTICSHYBRID VEHICLE CONTROL SYSTEM
2001 PRIUS (RM778U)
0: When engine is stopped
1: When stopping engine
2: When starting engine
DRIVE CONDITION3: When cranking engine or engine is operatingDRIVE CONDITION
4: While generating power or load driving
5: ±
6: While racing engine in P position
DRIVING PATTEN1History of driving pattern 1
DRIVING PATTEN2History of driving pattern 2
DRIVING PATTEN3History of driving pattern 3
DRIVING PATTERNHIstory of driving
ECU TYPEECU type
ENG INDPDET RQFactors causing engine to run independently
ENG STOP RQSTEngine stop request
ENG STP INHIBITEngine stop inhibition
ENG WARM UP RQTEngine warming up request
ENGINE FUEL CUTEngine fuel cut
ENGINE SPDEngine speed
EXCLUSIVE INFO1Exclusive information 1
EXCLUSIVE INFO2Exclusive information 2
EXCLUSIVE INFO3Exclusive information 3
EXCLUSIVE INFO4Exclusive information 4
EXCLUSIVE INFO5Exclusive information 5
EXCLUSIVE INFO6Exclusive information 6
FUEL SHORTAGELow fuel
HCAC ABSRT RQSTHCAC OBD request
HV BATT CH RQSTRequest from HV ECU to charge the battery
HV ECU INTERMITTENTHV ECU intermittent problems
IDLING REQUESTEngine idling request
IG OFF IN DRVINTurning IG OFF while driving the car
IG OFF TIMEIG OFF time
ILK OPERATIONInterlock operation
INFORMATION 1±5Information code
INPUT V LOWInput voltage is too low
INPUT V OVERInput voltage is too high
INTAKE AIRIntake air temperature
INVERT TEMP±MG1Temperature of inverter MG1
INVERT TEMP±MG2Temperature of inverter MG2
LATEST OPERLatest number of operation
LATEST TRIPLatest number of trips (IG ON±OFF)
LOAD CONDITIONIndicating which of MG1 or MG2 the vehicle uses more
MAIN BATT LOWSOC of main battery becomes low
MCYL CTRL POWERTorque for controlling oil pressure of master cylinder
MG1 TEMP HIGHTemperature MG1 is too high
MG2 TEMP HIGHTemperature MG2 is too high
MG1 CURRENT VElectric current of MG1 V phase

± DIAGNOSTICSHYBRID VEHICLE CONTROL SYSTEM
DI±195
2001 PRIUS (RM778U) MG1 CURRENT W
Electric current of MG1 W phase
MG1 INV TEMP HITemperature of inverter MG1 is high
MG1 REVMG1 revolution
MG1 TEMPMotor temperature of MG1
MG1 TEMP HIGHTemperature fo MG1 is too high
MG2 TEMP HIGHTemperature fo MG2 is too high
MG1 CURRENT VElectric cuurent of MG1 is V phase
MG1 CURRENT WElectric cuurent of MG1 is W phase
MG1 INV TEMP HITemperature of inverter MG1 is higt
MG1 REVMG1 revolution
MG1 TEMPMotor temperature of MG1
MG1 TEMP HIGHTemperature of MG1 is high
MG1 TORQMG1 torque
MG2 CURRENT VElectric cuurent of MG2 is V phase
MG2 CURRENT WElectric cuurent of MG2 is W phase
MG2 INV TEMP HITemperature of inverter MG2 is higt
MG2 REVMG2 revolution
MG2 TEMPMotor temperature of MG2
MG2 TEMP HIGHTemperature of MG2 is high
MG2 TORQMG2 torque
N RANGE OVR TIMELeaving shift gear into N position over a period of time
N RANGE CTRL1N position control due to incomplete shift gears
N RANGE CTRL2N position control due to rapid shift gear (D±R)
OCCURRENCE ORDROrder in which the trouble occurs
OCCURRNCE TRIPNumber of trips when this error occurred
OUTPUT STOPOutput stop
OUTPUT V OVEROutput voltage is too high
OVER CURRENTElectric current of the batytery is too high
OVER VOLTAGEVoltage of the battery is too high
OVR HEAT PRTECTOverheat protection
POWER RQSTPower output requested by HV ECU
PWR RESOURCE IBPower resource IB
PWR RESOURCE VMpower resource VM
RAPID SPD CHANGVehicle speed is changed too rapidly
REGEN EXEC TORQTorque volue of regenerative brake
REGEN IH FACTORInhibiting factor of regeneration
REGEN RQST TORQTorque valueof regenerative brake requested by HV ECU
REGN BRK INEFCTRegenerative brake is ineffective
RESIST OVR HEATRestriction resist is overheating
SG B IN REDUCINShifting gear into ºBº in reducing the speed
SG N IN REDUC/PShifting gear into ºNº reducing the speed
SHIFT BEF READYShifting gear before ºREADYº light turns on
SHIFT POSITIONShift position
SHIFT SENSOR1Shift sensor 1
SHIFT SENSOR2Shift sensor 2
SOCStated of charge

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)