2002 TOYOTA PRIUS battery

171
50p045a
Booster
battery
Negative
terminal
(“−
” mark) Jumper
cable
Discharged battery
Positive
terminal
(“+” mark)
c. Connect the clamp of the negative (black) jumper cable to the negative
(–) terminal on the booster battery.
d. Connect the clamp at the other end of the negative (black) jumper cable
to a solid, stationary, unpainted, me-
tallic point of the vehicle with the
discharged battery.
The recommended connecting point is
shown in the following illustrations:
50p043a
Connecting point
CAUTION
When making the connections, to
avoid serious injury, do not lean over
the battery or accidentally let the
jumper cables or clamps touch any-
thing except the correct battery termi-
nals or the ground.
10. Start the hybrid system. Make sure the “READY” light is on. If the hybrid ve-
hicle battery warning light comes on in
the multi −information display, the hybrid
vehicle battery is also discharged. Con-
tact your Toyota dealer.
11. Carefully disconnect the cables in the exact reverse order: the negative cable
and then the positive cable.
12. Carefully dispose of the battery cover cloths—they may now contain sulfuric
acid.
13. If removed, replace all the battery vent plugs.
If the cause of your auxiliary battery dis-
charging is not apparent (for example,
lights left on), you should have it checked.

187
Check the interior of your vehicle. Wa-
ter and dirt can accumulate under the
floor mats and could cause corrosion. Oc-
casionally check under the mats to make
sure the area is dry. Be particularly care-
ful when transporting chemicals, cleans-
ers, fertilizers, salt, etc.; these should be
transported in proper containers. If a spill
or leak should occur, immediately clean
and dry the area.
Keep your vehicle in a well ventilated
garage or a roofed place. Do not park
your vehicle in a damp, poorly venti-
lated garage. If you wash your vehicle in
the garage, or if you drive it in covered
with water or snow, your garage may be
so damp it will cause corrosion. Even if
your garage is heated, a wet vehicle can
corrode if the ventilation is poor.
60p001b
Your Toyota is a hybrid vehicle. Pay
particular attention when washing your
To y o t a .
NOTICE
Before washing your Toyota, be sure
to observe the following in order to
avoid the risk of damage to your ve-
hicle.
 Do not bring the tip of the nozzle
of the highlypressurized car wash
closer to the air vent on your
Toyota. If water enters, the hybrid
vehicle battery assembly might be
damaged.
 Do not splash water on the electric
components in the engine compart-
ment. This may cause the malfunc-
tion of the electric components.
Washing your Toyota
Keep your vehicle clean by regular
washing.
The following cases may cause weakness
to the paint or corrosion to the body and
parts. Wash your vehicle as soon as pos-
sible.
Washing and waxing your
To y o t a

198
Some states have vehicle emission in-
spection programs which include OBD
(On−Board Diagnostics) che cks.
The OBD system monitors the operation
of the emission control system. When the
OBD system determines that a problem
exists somewhere in the emission control
system, the malfunction indicator lamp
comes on. In this case, your vehicle may
not pass the I/M test and need to be
repaired. Contact your Toyota dealer to
service the vehicle.
Even if the malfunction indicator lamp
does not come on, your vehicle may not
pass the I/M test as readiness codes
have not been set in the OBD system.
Readiness codes are automatically set
during ordinary driving. However, when the
battery is disconnected or run down, the
codes are erased. Also, depending on
your driving habits, the codes may not be
completely set.
Also, if the malfunction indicator lamp had
come on recently due to temporary mal-
function such as a loose fuel tank cap,
your vehicle may not pass the I/M test. The malfunction indicator lamp will go off
after taking several driving trips, but the
error code in the OBD system will not be
cleared unless about 40 trips or more are
taken.
If your vehicle does not pass the I/M test
and the malfunction indicator lamp does
not come on, contact your Toyota dealer
to prepare the vehicle for re
−testing.
Emission inspection and
maintenance (I/M) programs

200
Engine compartment overview
1. Engine coolant reservoir
2. Fuse blocks
3. Brake fluid reservoir
4. Engine oil filler cap
5. Inverter reservoir tank
6. Windshield washer fluid tank
7. Radiator and condenser
8. Engine oil level dipstick
9. Auxiliary battery
81p001f

202
If you perform maintenance by yourself,
be sure to follow the correct procedure
given in this Section.
You should be aware that improper or in-
complete servicing may result in operating
problems.
Performing do−it−yourself maintenance
during the warranty period may affect your
warranty coverage. Read the separate
Toyota Warranty statement for details and
suggestions.
This Section gives instructions only for
those items that are relatively easy for an
owner to perform. As explained in Section
7, there are still a number of items that
must be done by a qualified technician
with special tools.
For information on tools and parts for do −
it −yourself maintenance, see ”Parts and
tools” on page 205 in this Section.
Utmost care should be taken when work-
ing on your vehicle to prevent accidental
injury. Here are a few precautions that
you should be especially careful to ob-
serve:CAUTION
When the hybrid system is on, keep
hands, clothing, and tools away
from the moving fan and engine
drive belts. (Removing rings,
watches, and ties is advisable.)
Right after driving, the engine
compartment—the engine, radiator,
exhaust manifold and spark plug
boots, etc.—will be hot. So be care-
ful not to touch them. Oil, fluids
and spark plugs may also be hot.
If the hybrid system is hot, do not
remove the radiator cap or loosen
the drain plugs to prevent burning
yourself.
Do not smoke, cause sparks or al-
low open flames around fuel or the
batteries. Their fumes are flam-
mable.
When the hybrid system is operat-
ing with the “READY” light on, the
engine is automatically started in
some case. When you inspect the
engine compartment, be sure to
turn the ignition switch to “OFF”
position.
Do not get under your vehicle with
just the body jack supporting it. Al-
ways use automotive jack stands or
other solid supports.
Be sure that the ignition is off if
you work near the electric cooling
fans or radiator grille. With the
ignition on, the electric cooling fans
will automatically start to run if the
engine coolant temperature is high
and/or the air conditioning is on.
Use eye protection whenever you
work on or under your vehicle
where you may be exposed to fly-
ing or falling material, fluid spray,
etc.
Be extremely cautious when work-
ing on the batteries. It contains poi-
sonous and corrosive sulfuric acid
or strong alkali.
Warning: Battery posts, terminals and
related accessories contain lead and
lead compounds, chemicals known to
the State of California to cause can-
cer and reproductive harm. Wash
hands after handling.
Doityourself service
precautions

205
Parts and tools
Here is a list of parts and tools you will
need on performing do−it−yourself mainte-
nance. Remember all Toyota parts are de-
signed in metric sizes, so your tools must
be metric.
CHECKING THE ENGINE OIL LEVEL
Parts (if level is low):
Engine oil API grade SJ “Energy −Con-
serving”, SL “Energy −Conserving” or IL-
SAC multigrade having viscosity proper
for your climate
Tools:
Rag or paper towel
Funnel (only for adding oil)
CHECKING THE COOLANT LEVEL
Parts (if level is low):
”TOYOTA Long Life Coolant” or equiva-
lent
See page 210 in Section 8 −2 for de-
tails about coolant type selection.
Demineralized or distilled water
Tools:
Funnel (only for adding coolant) CHECKING BRAKE FLUID
Parts (if level is low):
SAE J1703 or FMVSS No.116 DOT 3
brake fluid
Tools:
Rag or paper towel
Funnel (only for adding fluid)
CHECKING AUXILIARY BATTERY CON-
DITION
Tools:
Warm water
Baking soda
Grease
Conventional wrench (for terminal
clamp bolts)
CHECKING AND REPLACING FUSES
Parts (if replacement is necessary):
Fuse with same amperage rating as
original
ADDING WASHER FLUID
Parts:
Water
Washer fluid containing antifreeze (for
winter use) Tools:
Funnel
REPLACING LIGHT BULBS
Parts:
Bulb with same number and wattage
rating as original (See charts in ”Re-
placing light bulbs–” on page 225 in
Section 8 −3.)
Tools:
Screwdriver

221
DOITYOURSELF MAINTENANCE
Electrical components
Checking auxiliary battery condition 222
. . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary battery recharging precautionss 223
. . . . . . . . . . . . . . . . . . . . .
Checking and replacing fuses 223
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adding washer fluid 225
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . .
Replacing light bulbs 225
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . .
SECTION 8– 3

222
CAUTION
AUXILIARY BATTERY PRECAUTIONS
When the auxiliary battery must be
replaced, use the Prius designated
battery.
The auxiliary battery produces flam-
mable and explosive hydrogen gas.
Do not cause a spark from the bat-
tery with tools.
Do not smoke or light a match near
the battery.
The electrolyte contains poisonous
and corrosive sulfuric acid.
Avoid contact with eyes, skin or
clothes.
Never ingest electrolyte.
Wear protective safety glasses when
working near the battery.
Keep children away from the bat-
tery.
EMERGENCY MEASURES
If electrolyte gets in your eyes,
flush your eyes with clean water
and get immediate medical atten-
tion. If possible, continue to apply
water with a sponge or cloth while
en route to the medical office.
If electrolyte gets on your skin,
thoroughly wash the contact area. If
you feel pain or burn, get medical
attention immediately.
If electrolyte gets on your clothes,
there is a possibility of its soaking
through to your skin, so immediate-
ly take off the exposed clothing and
follow the procedure above, if nec-
essary.
If you accidentally swallow electro-
lyte, drink a large quantity of water
or milk. Follow with milk of magne-
sia, beaten raw egg or vegetable
oil. Then go immediately for emer-
gency help.
Warning: Battery posts, terminals and
related accessories contain lead and
lead compounds, chemicals known to
the State of California to cause can-
cer and reproductive harm. Wash
hands after handling.
Terminals
Ground cable
Hold−down clamp
Check the battery for corroded or loose
terminal connections, cracks, or loose
holddown clamp.
a. If the battery is corroded, wash it off with a solution of warm water and bak-
ing soda. Coat the outside of the termi-
nals with grease to prevent further cor-
rosion.
b. If the terminal connections are loose, tighten their clamp nuts—but do not
overtighten.
c. Tighten the hold− down clamp only
enough to keep the battery firmly in
place. Overtightening may damage the
battery case.
Checking auxiliary battery
condition—
—Precautions —Checking auxiliary battery
exterior