2003 TOYOTA PRIUS cooling

176
If your hybrid system stalls while driving...1. Reduce your speed gradually, keeping a straight line. Move cautiously off the
road to a safe place.
2. Turn on your emergency flashers.
3. Turn the ignition switch to ”OFF” posi- tion, and try starting the hybrid system
again.
If the hybrid system will not start, see “If
your vehicle will not start” on page 172.
CAUTION
If the hybrid system is not operating,
the power assist for the brakes and
steering will not work so steering and
braking will be much harder than usu-
al.
If your high coolant temperature warn-
ing light comes on, if you experience a
loss of power, or if you hear a loud
knocking or pinging noise, the hybrid
system has probably overheated. You
should follow this procedure... 1. Pull safely off the road, stop the ve- hicle and turn on your emergency
flashers. Put the transmission in “P”
and apply the parking brake. Turn off
the air conditioning if it is being used.
2. If coolant or steam is boiling out of the radiator or reservoir, stop the hybrid
system. Wait until the steam subsides
before opening the hood. If there is no
coolant boiling over or steam, leave the
hybrid system running and make sure
the electric cooling fan is operating. If
it is not, turn the ignition off.
CAUTION
To help avoid personal injury, keep
the hood closed until there is no
steam. Escaping steam or coolant is
a sign of very high pressure.
3. Look for obvious coolant leaks from theradiator, hoses, and under the vehicle.
However, note that water draining from
the air conditioning is normal if it has
been used.
CAUTION
When the hybrid system is running,
keep hands and clothing away from
the moving fan and engine drive
belts.
4. If the coolant is leaking, stop the hy-brid system immediately. Call a Toyota
dealer for assistance.
5. If there are no obvious leaks, check the coolant reservoir. If it is dry, add
coolant to the reservoir while the hy-
brid system is running. Fill it about half
full.
CAUTION
Do not attempt to remove the radiator
cap when the hybrid system and ra-
diator are hot. Serious injury could
result from scalding hot fluid and
steam blown out under pressure.
If your hybrid system stalls
while driving130. 131.If your vehicle overheats

208
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 doityourself 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
ityourself maintenance, see ”Parts and
tools” on page 211 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
precautions151.

216
Oil identification marks
Either or both API registered marks are
added to some oil containers to help
you select the oil you should use.
The API Service Symbol is located any-
where on the outside of the container.
The top portion of the label shows the oil
quality by API (American Petroleum Insti-
tute) designations such as SL. The center
portion of the label shows the SAE viscos-
ity grade such as SAE 5W30. “Energy
Conserving” shown in the lower portion,
indicates that the oil has fuelsaving ca-
pabilities.
The ILSAC (International Lubricant Stan-
dardization and Approval Committee) Certi-
fication Mark is displayed on the front of
the container.
To ensure excellent lubrication perfor-
mance for your engine, the “Toyota Genu-
ine Motor Oil” range is available, which
has been specifically tested and approved
for all Toyota engines.
Please contact your Toyota dealer for fur-
ther details of the “Toyota Genuine Motor
Oil” range.Look at the seethrough coolant reser-
voir when the hybrid system is cold.
The coolant level is satisfactory if it is
between the “FULL” and “LOW” lines
on the reservoir. If the level is low, add
ethyleneglycol type coolant for a prop-
er corrosion protection of aluminum
components.
The coolant level in the reservoir will vary
with hybrid system temperature. However,
if the level is on or below the “LOW” line,
add coolant. Bring the level up to the
“FULL” line.
Always use ethyleneglycol type coolant
for a proper corrosion protection of alumi-
num components. See information in the
next column.
If the coolant level drops within a short
time after replenishing, there may be a
leak in the system. Visually check the
radiator, hoses, radiator cap and drain
cock and water pump.
If you can find no leak, have your Toyota
dealer test the cap pressure and check
for leaks in the cooling system.
157.Checking the coolant level

217
CAUTION
To prevent burning yourself, do not
remove the radiator cap when the en-
gine is hot.
158.Coolant type selection
Use of improper coolants may damage
your cooling system. Your coolant must
contain ethyleneglycol type coolant for a
proper corrosion protection of your hybrid
system that contains aluminum compo-
nents. We have used “Toyota Genuine
Long Life Coolant” in your Toyota vehicle.
In order to avoid technical problems, we
strongly recommend using “Toyota Genu-
ine Long Life Coolant” or equivalent.
In addition to preventing freezing and sub-
sequent damage to the hybrid system, this
type of coolant will also prevent corrosion.
Further supplemental inhibitors or additives
are neither needed nor recommended.
Read the coolant container for information
on freeze protection. Follow the manufac-
turer’s directions for how much to mix
with plain water (preferably demineralized
water of distilled water). The total capacity
of the cooling system is given on page
242 in Section 9. We recommend to use 50% solution for
your Toyota, to provide protection down to
about 35
°C (31 °F). When it is extremely
cold, to provide protection down to about
50° C (58 °F), 60% solution is recom-
mended. Do not use more than 70% solu-
tion for better coolant performance.NOTICE
Do not use alcohol type antifreeze or
plain water alone.
The engine cooling system is integral to
maximizing performance of your Toyota
vehicle. In line with this, it is strongly
recommended that you use “Toyota Genu-
ine Long Life Coolant” for protecting the
system, as it is an ethyleneglycol based
premium antifreeze coolant with excellent
corrosion protection properties that has
been specifically formulated for use in
Toyota vehicles.
Please contact your Toyota dealer for fur-
ther details of the “Toyota Genuine Long
Life Coolant” range.

225
TIRE CHAIN SELECTION
Use the tire chains of correct size.
Regulations regarding the use of tire
chains vary according to location or
type of road, so always check them
before installing chains.
CHAIN INSTALLATION
Install the chains on the front tires as
tightly as possible. Do not use tire
chains on the rear tires. Retighten
chains after driving 0.5—1.0 km
(1/4—1/2 mile).
When installing chains on your tires, care-
fully follow the instructions of the chain
manufacturer.
If wheel covers are used, they will be
scratched by the chain band, so remove
the covers before putting on the chains.CAUTION
Do not exceed 50 km/h (30 mph) or
the chain manufacturer ’s recom-
mended speed limit, whichever is
lower.
Drive carefully avoiding bumps,
holes, and sharp turns, which may
cause the vehicle to bounce.
Avoid sharp turns or lockedwheel
braking, as use of chains may ad-
versely affect vehicle handling.
When driving with chains installed,
be sure to drive carefully. Slow
down before entering the curves to
avoid losing control of the vehicle.
Otherwise an accident may occur.
NOTICE
Do not attempt to use a tire chain on
the compact spare tire, as it may re-
sult in damage to the vehicle as well
as the tire.
WHEN TO REPLACE YOUR WHEELS
If you have wheel damage such as
bending, cracks or heavy corrosion, the
wheel should be replaced.
If you fail to replace damaged wheels, the
tire may slip off the wheel or cause loss
of handling control.
WHEEL SELECTION
When replacing wheels, care should be
taken to ensure that the wheels are re-
placed by ones with the same load ca-
pacity, diameter, rim width, and offset.
This must be observed on compact spare
tire, too.
Correct replacement wheels are available
at your Toyota dealer.
A wheel of a different size or type may
adversely affect handling, wheel and bear-
ing life, brake cooling, speedometer/odom-
eter calibration, stopping ability, headlight
aim, bumper height, vehicle ground clear-
ance, and tire or snow chain clearance to
the body and chassis.
166.Replacing wheels

240
Overall length mm (in.) 4305 (169.5)
Overall width mm (in.) 1695 (66.7)
Overall height mm (in.) 1465 (57.6)*
Wheelbase mm (in.) 2550 (100.4)
Front tread mm (in.) 1475 (58.1)
Rear tread mm (in.) 1480 (58.2)
Vehicle capacity weight
(occupants + luggage)kg (lb.) 363 (800)
*: Unladen vehicle
176.Electric motor
Type: Permanent magnet motor (water cooling)
Rated output: 20 kW
Maximum output: 33.0/1040 5600 kW/rpm
Maximum torque: 350.0/0 400 N·m/rpm Model: 1NZFXE
Type: 4cylinder in line, 4 cycle, gasoline
Bore and stroke, mm (in.):
75.0 x 84.7 (2.95 x 3.33)
Displacement, cm
3 (cu. in.):
1497 (91.4)
175.Dimensions and weight 177.Engine

242
ENGINE LUBRICATION
Oil capacity (drain and refill), L (qt, lmp.
qt.):
With filter 3.7 (3.9, 3.3)
Without filter 3.4 (3.6, 3.0)
“Toyota Genuine Motor Oil” is f illed in your
Toyota vehicle. Use Toyota approved “Toyota
Genuine Motor Oil” or equivalent to satisfy the
following grade and viscosity.
Oil grade:
API grade SL “EnergyConserving” or
ILSAC multigrade engine oil. Recommended oil viscosity:
SAE 5W30
oil008
Temperature range anticipated before next
oil change
Please contact your Toyota dealer for further
details. 181.COOLING SYSTEM
Total capacity, L (qt., Imp. qt.):
For gasoline engine 4.9 (5.2, 4.3)
For electric motor
and inverter and
converter 2.6 (2.7, 2.3)
Coolant type: “Toyota Genuine Long Life Coolant” is
filled in your Toyota vehicle. In order to
avoid technical problems, we strongly
recommend using “Toyota Genuine Long
Life Coolant” or equivalent.
Please contact your Toyota dealer for
further details.
With ethyleneglycol type coolant for a
proper corrosion protection of aluminum
components
Do not use alcohol type antifreeze or plain
water alone.
AUXILIARY BATTERY
Open voltage at 20 C (68 F):
12.6 12.8 V Fully charged
12.2 12.4 V Half charged
11.5 11.9 V Discharged
[Voltage that is checked 20 minutes after
the key is removed with all the lights
turned off]
Charging rates: 3.5 A max.

244
90p005a
Engine compartment
1. ABS NO.4 10 A: Antilock brake sys-
tem
2. HTR NO.1 30 A: Air conditioning sys-
tem
3. HTR NO.2 30 A: Air conditioning sys-
tem
4. DRL 7.5 A: Daytime running light sys-
tem
5. CDS FAN 30 A: Air conditioning sys-
tem
6. HORN 10 A: Horn
7. HEAD HI (RH) (Vehicles with Daytime running light system only) 10 A:
Righthand headlight (high beam)
90p006a
Engine compartment
8. AM2 15 A: Starting system, multiport
fuel injection system/sequential multi-
port fuel injection system, hybrid ve-
hicle immobiliser system
9. THRO 15 A: Electronic throttle control
system
10. HEAD (RH) (Vehicles without DAY- TIME RUNNING LIGHT SYSTEM) or
HEAD LO (RH) (Vehicles with DAY-
TIME RUNNING LIGHT SYSTEM) 10
A: Righthand headlight
11. HEAD HI (LH) (Vehicles without DAY- TIME RUNNING LIGHT SYSTEM) 10
A: Lefthand headlight (high beam)
90p007a
Instrument panel
12. BATT FAN 10 A: Battery cooling fan
13. ABS NO.3 20 A: Hydraulic brake
booster
14. HV 20 A: Hybrid system
15. EFI 15 A: Multiport fuel injection sys-
tem/sequential multiport fuel injection
system
16. HEAD (LH) (Vehicles without DAY- TIME RUNNING LIGHT SYSTEM) or
HEAD LO (LH) (Vehicles with DAY-
TIME RUNNING LIGHT SYSTEM) 10
A: Lefthand headlight
183.Fuses