2004 TOYOTA PRIUS battery

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

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

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.

315
22. IGN 7.5 A: Hybrid system, hybrid ve-
hicle immobilizer system, SRS air bags
23. SPARE 30 A: Spare
24. SPARE 15 A: Spare
25. DRL 7.5 A: Daytime running light sys-
tem
26. HLP LO RH 15 A (Vehicles with dis- charged headlight) or 10 A (Vehicles
with halogen headlight): Right−hand
headlight (low beam)
27. HLP LO LH 15 A (Vehicles with dis- charged headlight) or 10 A (Vehicles
with halogen headlight): Left−hand
headlight (low beam)
28. HLP HI RH 10 A: Right−hand head-
light (high beam)
29. HLP HI LH 10 A: Left−hand headlight
(high beam)
30. EFI 15 A: Multiport fuel injection sys-
tem/sequential multiport fuel injection
system
31. AM2 15 A: “IGN” fuse, ignition system
32. HORN 10 A: Horn
33. HEV 20 A: Hybrid system
34. P CON MAIN 7.5 A: Parking control
system, hybrid vehicle immobilizer sys-
tem 35. P CON MTR 30 A:
Parking control
system or ABS1 25 A: Anti−lock
brake system
36. ETCS 10 A: Electronic throttle control
system
37. BATT FAN 10 A: Battery cooling fan
38. HAZ 10 A: Turn signal lights, emergen-
cy flasher
39. DOME 15 A: Audio system, interior
lights, smart entry and start system,
gauge and meter, turn signal lights,
luggage room light, clock
40. ABS MAIN3 15 A: Anti−lock brake sys-
tem
41. ABS MAIN2 10 A: Anti−lock brake sys-
tem
42. ABS MAIN1 10 A: Anti−lock brake sys-
tem
43. FR FOG 15 A: Fog lights
44. CHS W/P 10 A: CHS W/P
45. AMP 30 A: Audio system
46. PTC HTR2 30 A: PTC heater
47. PTC HTR1 30 A: PTC heater
48. CDS FAN 30 A: Electric cooling fan
49. DC/DSS 5 A: Inverter and converter
50. MAIN 120 A: Hybrid system

324
Important health andsafety information about your
To y o t a
CAUTION
WARNING: Engine exhaust, some of its constitu-
ents, and a wide variety of automobile compo-
nents contain or emit chemicals known to the
State of California to cause cancer and birth de-
fects and other reproductive harm. In addition,
oils, fuels and fluids contained in vehicles as well
as waste produced by component wear contain or
emit chemicals known to the State of California
to cause cancer and birth defects or other repro-
ductive harm.
Battery posts, terminals and related accessories
contain lead and lead compounds. Wash your
hands after handling. Used engine oil contains
chemicals that have caused cancer in laboratory
animals. Always protect your skin by washing
thoroughly with soap and water.

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.