2005 TOYOTA PRIUS battery

300
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 262.
Checking auxiliary battery
condition—
—Precautions —Checking auxiliary battery
exterior

301
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 42 and “Back door” on page 41.
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.

302
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

311
SPECIFICATIONS
Dimensions and weight312
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
.
Electric motor 312
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . . .
Enginee 312
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . . . . . . . .
Fuel 313
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . . . . . . . . . . . .
Hybrid vehicle battery 313
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . .
Service specifications 313
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . .
Tires 315
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . . . . . . . . . . .
Fuses 316
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . . . . . . . . . .
SECTION 9

313
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

315
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
Please contact your Toyota dealer for further
details. 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
291 through 298.

317
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. 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

328
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.