2004 TOYOTA PRIUS fuel cap

272
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.
Emissions inspection and
maintenance (I/M) programs

276
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 279.
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 leave anything that may
burn easily, such as paper or rags,
in the engine compartment.
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
press the “POWER” switch to the
“OFF” mode.
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 hybrid system is
in the “OFF” mode if you work near
the electric cooling fans or radiator
grille. With the ignition on, the
electric cooling fans will automati-
cally start to run if the engine cool-
ant 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.
Doityourself service
precautions

284
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 5W−30. “Energy −
Conserving” shown in the lower portion,
indicates that the oil has fuel −saving 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, “Toyota Genuine
Motor Oil” is available, which has been
specifically tested and approved for all
Toyota engines.
Please contact your Toyota dealer for fur-
ther details about “Toyota Genuine Motor
Oil”.
CAUTION
The coolant heat storage tank reaches
high temperature inside. It is danger-
ous if hot coolant is discharged when
replacing. For replacement of the
coolant, contact your Toyota dealer.
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
the coolant. (For the coolant type, see
“Coolant type selection” described be-
low.)
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.
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.
Checking the coolant level

286
If any of the above parts are extremely
dirty or you are not sure of their condi-
tion, take your vehicle to a Toyota dealer.
CAUTION
To prevent burning yourself, be care-
ful not to touch the radiator or con-
denser when the engine is hot.
NOTICE
To prevent damage to the radiator
and condenser, do not perform the
work by yourself.
Checking brake fluid
82p002b
To check the fluid level, simply look at
the seethrough reservoir. The level
should be between the “MAX” and
“MIN” lines on the reservoir.
It is normal for the brake fluid level to go
down slightly as the brake pads wear or
when the fluid level in the accumulator is
high.
If the reservoir needs frequent refueling,
it may indicate a serious mechanical prob-
lem.
If the level is low, add SAE J1703 or
FMVSS No. 116 DOT 3 brake fluid to
the brake reservoir.Refilling brake fluid:
1. Turn the hybrid system off.
2. Depress the brake pedal more than 40 times.
3. Remove the reservoir cap by hand. Add brake fluid up to the “MAX” line.
If you do not follow the procedure above,
the reservoir may overflow.
Use only newly opened brake fluid. Once
opened, brake fluid absorbs moisture from
the air, and excess moisture can cause a
dangerous loss of braking.CAUTION
Take care when filling the r eservoir
because brake fluid can harm your
eyes and damage painted surfaces. If
fluid gets in your eyes, flush your
eyes with clean water immediately. If
you still feel uncomfortable with your
eyes, go to the doctor.
NOTICE
If you spill the fluid, be sure to wipe
it off to prevent it from damaging the
parts or painting.
Checking the radiator and
condenser

290
Always use a tire inflation pres-
sure gauge. The appearance of
a tire can be misleading. Besides,
tire inflation pressures that are
even just a few pounds off can de-
grade ride and handling.
 Take special care when adding
air to the compact spare tire.
The smaller tire size can gain
pressure very qu ickly. Add com-
pressed air in small quantities and
check the pressure often until it
reaches the specified pressure.
 Do not bleed or reduce tire
inflation pressure after driving.
It is normal for the tire inflation
pressure to be higher after driving.
 Never exceed the vehicle capac-
ity weight. Passenger and lug-
gage weight should be located so
that the vehicle is balanced.
Ti r e inf lat ion
pressure gauge
INSPECTION AND ADJUSTMENT
PROCEDURE 1. Remove the tire valve cap.
2. Press the tip of the tire inflation pressure gauge to the tire valve.
3. Read the pressure using the grad- uations of the gauge.
4. In case the tire inflation pressure
is not within the prescribed range,
insert the compressed air from the
valve. In case of applying too much
air, press the center of the valve
and release the air to adjust. 5. After completing the tire inflation
pressure measurement and adjust-
ment, apply soapy water to the
valve and check for leakage.
6. Install the tire valve cap.
If a gauge and air pump are not avail-
able, have your vehicle checked by
your Toyota dealer.
CAUTION
Be sure to reinstall the tire valve
caps. Without the valve caps, dirt
or moisture could get into the
valve core and cause air leakage.
If the caps have been lost, have
new ones put on as soon as pos-
sible.
Incorrect tire inflation pressure
may waste fuel, reduce the comfort
of driving, reduce tire life and
make your vehicle less safe to
drive.
If a tire frequently needs refilling,
have it checked by your Toyota deal-
er.

311
Fuel type:Unleaded gasoline, Octane Rating 87
(Research Octane Number 91) or
higher
Fuel tank capacity, L (gal., lmp. gal.): 45 (11.9, 9.9)
Hybrid vehicle battery
Type: Nickel −Metal hydride battery
Voltage: 7.2 V
Capacity: 6.5 Ah (3HR)
Quantity: 28
Overall voltage: 201.6 V
Service specifications
ENGINE
Valve clearance (engine cold), mm (in.): Intake 0.17—0.23 (0.007—0.009)
Exhaust 0.27—0.33 (0.011—0.013)
Spark plug type: DENSO SK16R11
NGK IFR5A11
Spark plug gap, mm (in.): 1.1 (0.043)
Fuel

2
Publication No. OM47482U
Part No. 01999-47482
Printed in Japan 04−0407 −01
U 5Quick index
 If a service reminder indicator or warning buzzer comes on 117 . . .
 If your vehicle will not start 238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 If your vehicle overheats 242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
.
 If you have a flat tire 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . .
 If your vehicle needs to be towed 254 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 Tips for driving during break-in period 202 . . . . . . . . . . . . . . . . . . . . . . . . . .
 How to start the hybrid system 230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 General maintenance 269 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . .
Gas station information
Fuel type:
UNLEADED gasoline, Octane Rating 87 (Research Octane Number 91)
or higher.
See page 202 for detailed information.
Fuel tank capacity:
45 L (11.9 gal., 9.9 lmp. gal.)
See page 204 for detailed information.
Engine oil:
API grade SL “Energy −Conserving” or ILSAC multigrade engine oil
is recommended.
See page 283 for detailed information.
Tire information: See pages 289 through 296.
Tire inflation pressure: See page 313.
C