2004 TOYOTA PRIUS service

273
DOITYOURSELF MAINTENANCE
Introduction
Engine compartment overview274
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse locations 275
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . .
Do −it− yourself service precautions 276
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Positioning the jack 278
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . .
Parts and tools 279
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . .
SECTION 8– 1

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

283
ENGINE OIL SELECTION
“Toyota Genuine Motor Oil” is used in
your Toyota vehicle. Use Toyota approved
“Toyota Genuine Motor Oil” or equivalent
to satisfy the following grade and viscos-
ity.
Oil grade:API grade SL “Energy −Conserving” or
ILSAC multigrade engine oil.
Recommended viscosity:
SAE 5W −30
oil008
Outside temperature
SAE 5W30 is the best choice, for good
fuel economy, and good starting in cold
weather. If SAE 5W30 oil is not available, SAE
10W30 oil may be used. However, it
should be replaced with SAE 5W30 at
the next oil change.
82P103
API service symbol
ILSAC certification mark

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

309
SPECIFICATIONS
SPECIFICATIONS
Dimensions and weight310
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
.
Electric motor 310
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . . .
Enginee 310
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . . . . . . . .
Fuel 311
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . . . . . . . . . . . .
Hybrid vehicle battery 311
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . .
Service specifications 311
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . .
Tires 313
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . . . . . . . . . . .
Fuses 314
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . . . . . . . . . .
SECTION 9

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

327
Scrapping of your Toyota
The SRS airbag and seat belt pre-
tensioner devices in your Toyota
contain explosive chemicals. If the
vehicle is scrapped with the airbags
and pretensioners left as they are,
this may cause an accident such as
fire. Be sure to have the systems
of the SRS airbag and seat belt
pretensioner removed and disposed
of by the qualified service shop or
by your Toyota dealer before you
dispose of your vehicle.
CAUTION
When your vehicle or bat-
tery needs to be disposed
of, be sure to consult your
Toyota dealer. Hybrid ve-
hicle batteries must be
collected through Toyota
dealers. If your vehicle is
disposed of without dis-
mantling, someone could
receive an electric shock
by touching the high volt-
age parts of the hybrid ve-
hicle battery. If the battery
is not disposed of proper-
ly, its contents can cause
death or serious injury.
Hybrid vehicle battery
The hybrid vehicle battery has a
limited service life. Call your Toyo-
ta dealer for information about re-
cycling or disposal of hybrid ve-
hicle battery and your vehicle.

329
Precautions for useof hybrid vehicle
The vehicle has both high voltage
DC and AC systems as well as a
12volt system. DC and AC high
voltage are both very dangerous
and can cause death or serious inju-
ry, severe burns and electric shock.
In order to avoid personal in-
juries, do not touch the high
voltage cables (orange col-
ored) and their connectors.
Follow the caution labels at-
tached to the high voltage
parts.
Do not remove or replace the
high voltage parts such as
the inverter unit (located in
the engine compartment), hy-
brid vehicle battery (located
behind rear seat), etc.
Do not touch the service plug
located in the left side trim
of the luggage compartment
without hybrid system techni-
cal training. (See “Precau-
tions for use” on page 12 in
Section 12.) This component
is provided to disable the
high voltage system in case
of servicing at a Toyota deal-
er.
CAUTIONIf an accident occurs
Pull your vehicle off the road,
push the “P” position switch,
stop the hybrid system and if
the key is inserted into key
slot, remove it.
In order to avoid personal in-
juries, do not touch any high
voltage wirings and their con-
nectors, and high voltage
parts (inverter unit, hybrid ve-
hicle battery, etc.).
If some exposed electric
wires are protruding inside or
outside of your vehicle, an
electric shock may occur.
Never touch the electric
wires.
If fluid leaks or gets in some
parts of the vehicle, never
touch it because it may be
electrolyte (strong alkali) from
the hybrid vehicle battery. If
it gets into your skin or eyes,
wash off immediately with a
large amount of water, if pos-
sible, boric acid solution, and
get immediate medical atten-
tion in order to help avoid
serious injury.
If a vehicle fire occurs, extin-
guish it using a fire extin-
guisher for the exclusive use
on electric fires. Or, use a
large amount of water to pre-
vent flammable gas from be-
ing generated from the batter-
ies.