2004 TOYOTA PRIUS auxiliary battery

279
Parts and tools
Here is a list of parts and tools you will
need to perform 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 SL “Energy −Con-
serving” or ILSAC 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 Super Long Life Coolant” or
similar high quality ethylene glycol
based non− silicate, non −amine, non− ni-
trite, and non −borate coolant with long −
life hybrid organic acid technology.
“Toyota Super Long Life Coolant” is a
mixture of 50% coolant and 50% deion-
ized water (for the U.S.A.) or 55%
coolant and 45% deionized water (for
Canada).
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 302.)
Tools:
Screwdriver

297
DOITYOURSELF MAINTENANCE
Electrical components
Checking auxiliary battery condition 298
. . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary battery recharging precautionss 300
. . . . . . . . . . . . . . . . . . . . .
Checking and replacing fuses 300
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adding washer fluid 302
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . .
Replacing light bulbs 302
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . .
SECTION 8– 3

298
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.
83p035
Open the back door. Remove the lug-
gage storage box and auxiliary battery
cover.
If the back door does not open, see “If
you cannot operate back door opener” on
page 258.
Checking auxiliary battery
condition—
—Precautions —Checking auxiliary battery
exterior

299
83p001c
Terminals
Ground
cableHold−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.
NOTICE
 Be sure the hybrid system and all
accessories are off before perform-
ing maintenance.
 When checking the battery, remove
the ground cable from the negative
terminal (“–” mark) first and rein-
stall it last.
 Be careful not to cause a short cir-
cuit with tools.
 Take care no solution gets into the
battery when washing it.
If the auxiliary battery is disc onnected
or run down, the power window and back
door may not operate automatically and
the jam protection function will not func-
tion correctly and does not open the back
door after you reconnect, replace or re-
charge the battery. In any of these cases,
you should normalize each system. To
normalize them, see “Power windows” on
page 40 and “Back door” on page 39.
Before you disconnect the auxiliary bat-
tery, confirm the shift position is “P” and
apply the parking brake completely. After you reconnect the auxiliary battery,
shift the shift lever to “N” and confirm the
shift position is “N” when the “IG
−ON”
mode is enabled.
After connecting the cables, the hybrid
system may not start by pushing the
“POWER” switch. In that case, push it
once again.

300
During recharging, the battery is pro-
ducing hydrogen gas.
Therefore, before recharging:1. If recharging with the battery installed on the vehicle, be sure to disconnect
the ground cable.
2. Make sure the power switch on the recharger is off when connecting the
charger cables to the battery and when
disconnecting them.
CAUTION
Always charge the battery in an un-
confined area. Do not charge the
battery in a garage or closed room
where there is not sufficient ventila-
tion.
Only do a slow charge (3.5A or
less). Charging at a quicker rate is
dangerous. The battery may ex-
plode, causing personal injuries.
NOTICE
Never recharge the battery with the
hybrid system on. Also, be sure all
accessories are turned off.
83p003
Type A
Type B
Type C Good Blown
Good Blown
Good Blown
Auxiliary battery recharging
precautions
Checking and replacing fuses

313
AUXILIARY BATTERY
Open voltage at 20C (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.
HYBRID TRANSAXLE
Fluid capacity (drain and refill),
L (qt., Imp. qt.): 3.6 (3.8, 3.2)
Fluid type: “Toyota Genuine ATF WS” or
equivalent BRAKES
Minimum pedal clearance when depressed
with the force of 196 N (20 kgf, 44 lbf)
with the traction motor running, mm (in.):
101.0 (3.98)
Pedal free play, mm (in.): 1 − 4 (0.04 − 0.16)
Parking brake adjustment when depressed
with the force of 294 N (30 kgf, 66 lbf): 6 − 9 clicks
Fluid type: SAE J1703 or FMVSS No. 116 DOT 3
STEERING
Wheel free play: Less than 30 mm (1.2 in.)
Tires
Tire size and inflation pressure:
Tire size kPa (kgf/cm
2 or ba r, ps i )
Standard Front P185/65R15 86S
240 (2. 4, 35)
Rear
P185/65R15 86S 230 (2. 3, 33)
Spare T125/70D16 96M
420 (4. 2, 60)
Wheel size: Standard 15 x 6JJ
S par e 16 x 4T
Wheel nut torque, N·m (kgf·m,
ft·lbf): 103 (10.5, 76)
NOTE: For a complete information on tires (e.g. replacing tires
or replacing wheels), see
“Checking tire inflation pres-
sure” through “Aluminum
wheel precautions”, page
289 through 296.