Toyota Prius 2004 Manual
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HOW TO USE THIS MANUAL

GENERAL INFORMATION
1.
GENERAL DESCRIPTION
(a)
This manual is written in accordance with SAE J2008.
(b)
Repair operations can be separated into 3 main processes:
1. Diagnosis
2. Removing/Installing, Replacing, Disassembling/Reassembling, Checking and Adjusting
3. Final Inspection
(c)
This manual explains the "Diagnosis" (found in the "Diagnostics" section) and "Removing and Instal-
ling, Replacing, Disassembling, Installing and Checking, and Adjusting". "Final Inspection" is omitted.
(d)
The following essential operations are not written in this manual. However, these operations must be
performed in actual situations.
(1)
Operations with a jack or lift
(2)
Cleaning of a removed part when necessary
(3)
Visual check
(e)
The "< >" marks highlight the part's name in the Parts Catalog.
2.
INDEX
(a)
An alphabetical INDEX section is provided at the end of the book as a reference to help you find the
item to be repaired.
3.
PREPARATION
(a)
Use of Special Service Tools (SST) and Special Service Materials (SSM) may be required, depending
on the repair situation. Be sure to use SST and SSM when they are required and follow the working
procedure properly. A list of SST and SSM is in the Preparation section of this manual.
4.
REPAIR PROCEDURES
(a)
A component illustration is placed under the title where necessary.
(b)
Non–reusable parts, grease application areas, precoated parts and torque specifications are noted
in the component illustrations.
Example:
Slotted Spring Pin
15 (155, 11)
Cylinder
N·m (kgf·cm, ft·lbf)
: Specified torque
D Non–reusable part
2004 Prius – Preliminary Release (RM1075U)
INTRODUCTION
Filler Cap
Float
Reservoir Tank
D Grommet
12 (120, 9)
Piston
2004 Prius – Preliminary Release (RM1075U)
D Gasket
Boot
Snap Ring
Washer
Push Rod
Author :
01–1
010RX–01
Clevis Pin
Clip
Clevis
Lock Nut
N17080
Date :
1

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Summary of Contents for Toyota Prius 2004

  • Page 1: How To Use This Manual

    01–1 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) HOW TO USE THIS MANUAL 010RX–01 GENERAL INFORMATION GENERAL DESCRIPTION This manual is written in accordance with SAE J2008. Repair operations can be separated into 3 main processes: 1. Diagnosis 2. Removing/Installing, Replacing, Disassembling/Reassembling, Checking and Adjusting 3.
  • Page 2: Service Specifications

    01–2 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) Torque specifications, grease application areas, and non–reusable parts are emphasized in the proce- dures. NOTICE: There are cases where such information can only be explained by using an illustration. In these cases, all the information such as torque, oil, etc.
  • Page 3 01–3 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) SI UNIT The units used in this manual comply with the SI UNIT (International System of Units) standard. Units from the metric system and the English system are also provided. Example: Torque: 30 N m (310 kgf cm, 22 ft lbf) 2004 Prius –...
  • Page 4: Identification Information

    01–4 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) IDENTIFICATION INFORMATION 010RY–01 VEHICLE IDENTIFICATION AND SERIAL NUMBERS VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the ve- hicle identification number plate and certification label, as shown in the illustration. A: Vehicle Identification Number Plate B: Certification Label B76081...
  • Page 5: Repair Instruction

    01–5 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) REPAIR INSTRUCTION 010RZ–01 PRECAUTION BASIC REPAIR HINT HINTS ON OPERATIONS B73283 D Always wear a clean uniform. Looks D A hat and safety shoes must be worn. D Prepare a grille cover, fender cover, seat cover and floor mat before starting the repairs. Vehicle protection D When working with 2 or more persons, be sure to check safety for one another.
  • Page 6 01–6 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) JACKING UP AND SUPPORTING VEHICLE Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations (see page 01–34). PRECOATED PARTS Precoated parts are bolts and nuts that are coated with a seal lock adhesive at the factory.
  • Page 7 01–7 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) CLIPS The removal and installation methods of typical clips used in body parts are shown in the table below. HINT: If clips are damaged during a procedure, always replace the damaged clip with a new clip. Shape (Example) Removal/Installation Clip...
  • Page 8 01–8 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) Removal/Installation Shape (Example) Removal Installation Screwdriver Push Clip Remover Remove rivet by pushing the center pin through and prying out the rivet shell. Removal Installation Screwdriver Push Clip Remover Remove rivet by unscrewing the center pin and prying out the rivet shell.
  • Page 9 01–9 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) REMOVAL AND INSTALLATION OF VACUUM HOSES To disconnect vacuum hoses, pull and twist from INCORRECT CORRECT the end of the hose. Do not pull from the middle of the hose as this may cause damage. D31750 When disconnecting vacuum hoses, use tags to identify where they should be reconnected.
  • Page 10 01–10 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) PRECAUTIONS FOR HIGH–VOLTAGE CIRCUIT IN- SPECTION AND SERVICE Engineer must undergo special training to be able to per- form high–voltage system inspection and servicing. All high–voltage wire harness connectors are colored orange.
  • Page 11 01–11 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) After servicing the high–voltage system and before rein- stalling the service plug, check again that you have not left a part or tool inside, that the high–voltage terminal screws are firmly tightened, and that the connectors are correctly connected.
  • Page 12 01–12 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION. Person in charge: Copy this page and put it after folding on the roof of the vehicle in service. B75514 2004 Prius – Preliminary Release (RM1075U) Author : Date :...
  • Page 13 01–13 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) PRECAUTIONS TO BE OBSERVED WHEN INSPECT- ING OR SERVICING ENGINE COMPARTMENT The PRIUS automatically turns the engine ON and OFF when the READY light on the instrument panel is ON. To avoid injury, remove the key from the key slot before inspecting or servicing the engine compartment.
  • Page 14 01–14 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) INSPECTION MODE HINT: The PRIUS’ engine automatically stops if the vehicle is stopped, the engine is warmed up, the battery is well charged, and A/C compressor operation is not being used. Activate inspection mode when con- tinuous operation of the engine is required.
  • Page 15 01–15 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) Activate inspection mode. Check that the HV sys- tem warning on the multi–information display starts blinking and master warning lamp on the combina- tion meter is illuminated. Depress and hold the brake pedal, and then push the power switch.
  • Page 16 01–16 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) Visually check the HV battery and immediate area for any electrolyte leakage. Do not touch any leaked liquid because it could be highly alkaline electrolyte. Wear rubber gloves and goggles, and then apply red litmus paper to the leak. If the paper turns blue, the liquid must be neutralized before wiping.
  • Page 17 01–17 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) Remove the service plug while wearing insulated Service Plug gloves. Do not turn the power switch on while removing the service plug. B75497 If the service plug cannot be removed due to dam- Engine Room J/B age to the rear portion of the vehicle, remove the HV fuse or power integration (IGCT Relay) instead.
  • Page 18 01–18 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) Actions required after moving the damaged vehicle If you see any liquid on the road surface, it could be highly alkaline electrolyte leakage. Wear rubber gloves and goggles, and apply red litmus pa- per to the leak.
  • Page 19 01–19 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) If the electrolyte comes in contact with your eyes, call out loudly for help. Do not rub your eyes. Wash them with a large amount of water and seek medical care immediately. If damage to any of the high–voltage components and cables is suspected, cut the high–voltage cir- cuit using the procedure below.
  • Page 20: General Notice

    01–20 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER HINT: The PRIUS is equipped with a Supplemental Restraint System (SRS) and seat belt pretensioner. Failure to carry out the service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing and lead to serious injury.
  • Page 21 01–21 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) SPIRAL CABLE (in Combination Switch) The steering wheel must be fitted correctly to the steering column with the spiral cable in the neutral position, otherwise cable disconnection and other problems may occur. Refer to page 60–29 for in- Mark...
  • Page 22 01–22 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) INSTRUMENT PANEL PASSENGER AIRBAG ASSY Always place a removed or new instrument panel passenger airbag assembly with the airbag inflation direction facing upward. Placing the airbag assembly with the airbag inflation direction facing downward could cause a serious accident if the airbag inflates.
  • Page 23 01–23 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and electrical noise is not nearby. When using electric welding anywhere on the vehicle, disconnect the airbag sensor (ECU) con- nectors (2 pins).
  • Page 24: Seat Belt Pretensioner

    01–24 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) Example: NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER D30924 SEAT BELT PRETENSIONER Never measure the resistance of the seat belt pretensioner. This may cause the seat belt preten- sioner to activate, which could cause serious injury. Never disassemble the seat belt pretensioner.
  • Page 25 01–25 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) ELECTRONIC CONTROL Negative (–) REMOVAL AND INSTALLATION OF BATTERY TERMI- Terminal NOTICE: After disconnecting the negative (–) terminal, it is neces- sary to perform the initialization of certain systems. (see page 01–28) Before performing electronic work, disconnect the battery negative (–) terminal cable beforehand to D25080...
  • Page 26 01–26 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS PLACE FOR REMOVING AND INSTALLING OF FUEL SYSTEM PARTS Work in a place with good air ventilation that does not have welders, grinders, drills, electric mo- tors, stoves, or any other ignition sources.
  • Page 27 01–27 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) FOR VEHICLES EQUIPPED WITH VEHICLE STABIL- DLC3 ITY CONTROL (Enhanced VSC) SYSTEM NOTICES WHEN USING DRUM TESTER Before beginning testing, disable the Vehicle Skid Control (Enhanced VSC) system. To disable the En- 1 2 3 4 5 6 7 8 hanced VSC, change the power switch’s power 1314 1516...
  • Page 28 01–28 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) 010S0–01 INITIALIZATION NOTICE: When disconnect the negative (–) battery terminal, initialize the following systems after the terminal is reconnected. System Name See Step No. Power Window Control System Step 1 RESET (INITIALIZE) POWER WINDOW REGULATOR MOTOR (DRIVER SIDE) NOTICE: Resetting the power window regulator motor (initializing the pulse sensor) is necessary if: 1) the battery terminal cable is disconnected;...
  • Page 29: Air Conditioner

    01–29 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) 010S1–01 CUSTOMIZE PARAMETERS HINT: The following can be customized. NOTICE: After confirming whether the items of the customer’s request are applicable or not for the cus- tomized items, perform the customize operation. Be sure to record the current value before customizing.
  • Page 30: Light Control

    01–30 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) LIGHT CONTROL DISPLAY (ITEM) DEFAULT CONTENTS SETTING LIGHT2 / LIGHT1 / NOR- To adjust the sensitivity of the lighting illumination. SENSITIVITY NORMAL Refer to the *1 illustration. MAL / DARK1 / DARK2 Changes the brightness when lowering lights such as the LIGHT2 / LIGHT1 / NOR- DISP EX ON SEN...
  • Page 31: Smart Entry System

    01–31 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) HINT: The setting can be reset when reconnecting the battery connector or removing/installing the meter connec- tor(Buzzer on). SMART ENTRY SYSTEM Display (Item) Default Contents Setting SMART WARN 1 Function that warns driver that key is taken out from driver’s (Warn key is taken from ON/OFF door when shift position is in P and power switch is not OFF...
  • Page 32 01–32 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) WIRELESS DOOR LOCK: w/ Smart Entry System Display (item) Default Contents Setting If door is not completely closed and transmitter LOCK switch OPEN DOOR WARN is pressed, this function makes buzzer sound for 10 se- ON/OFF (Open door warning) conds.
  • Page 33: Theft Deterrent System

    01–33 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) Theft deterrent system DISPLAY (ITEM) DEFAULT CONTENTS SETTING PASSIVE MODE is a function that switches theft deterrent system from arming preparation state to armed state 30 se- conds after key is removed from key slot and all doors is closed, even if doors are not locked by wireless or door key lock operation PASSIVE MODE...
  • Page 34: Vehicle Lift And Support Locations

    01–34 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) 010S2–01 VEHICLE LIFT AND SUPPORT LOCATIONS NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP The vehicle must be unloaded before jacking up the vehicle. Never jack up/lift up a heavily loaded ve- hicle.
  • Page 35 01–35 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) NOTICE FOR USING SWING ARM TYPE LIFT Follow the safety procedures outlined in its instruction manual. Use swing arms equipped with rubber attachments, as shown in the illustration. When using the lift, its center should be as close to the vehicle’s center of gravity as possible. Set the vehicle on the lift as level as possible.
  • Page 36: How To Troubleshoot Ecu Controlled Systems

    01–36 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 010S3–01 GENERAL INFORMATION A large number of ECU controlled systems are used in the PRIUS. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system’s circuits one by one.
  • Page 37: How To Proceed With Troubleshooting

    01–37 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) 010S4–01 HOW TO PROCEED WITH TROUBLESHOOTING HINT: Carry out troubleshooting in accordance with the procedures below. Only a basic procedure is shown. De- tails in the Diagnostic Section show the most effective methods for each circuit. Confirm the troubleshooting procedures for the relevant circuit before beginning troubleshooting.
  • Page 38 01–38 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) REPAIR Repair the affected system or part according to the instructions in step 6. CONFIRMATION TEST After completing repairs, confirm that the problem has been solved. If the problem does not recur, per- form a confirmation test under the same conditions and in the same environment as when it occurred the first time.
  • Page 39: Customer Problem Analysis Check

    01–39 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) CUSTOMER PROBLEM ANALYSIS HINT: In troubleshooting, the problem symptoms must be confirmed accurately. Preconceptions should be discarded in order to give an accurate judgement. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time it occurred.
  • Page 40: Dtc Check

    01–40 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT: The diagnostic system in the PRIUS has various functions. The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs.
  • Page 41 01–41 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR THE MEMORY SYMPTOM CONFIRMATION Symptoms exist No symptoms exist Go to step 5 SIMULATION TEST USING SYMPTOM SIMULATION METHODS DTC CHECK DTC displayed No DTC displayed TROUBLESHOOTING PROBLEM...
  • Page 42: Symptom Simulation

    01–42 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) SYMPTOM SIMULATION HINT: The most difficult case in troubleshooting is when no problem symptoms occur. In such cases, a thorough customer problem analysis must be carried out. A simulation of the same or similar conditions and environ- ment in which the problem occurred in the customer’s vehicle should be carried out.
  • Page 43 01–43 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) WATER SPRINKLING METHOD: When the malfunc- tion seems to occur on a rainy day or in high humidity. Sprinkle water onto the vehicle and check if the malfunc- tion occurs. NOTICE: Never sprinkle water directly into the engine compart- ment.
  • Page 44: Diagnostic Trouble Code Chart

    01–44 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) DIAGNOSTIC TROUBLE CODE CHART Use Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the table below to determine the trouble area and proper inspection procedure. The Supplemental Restraint System (SRS) DTC chart is shown be- low as an example.
  • Page 45: Problem Symptoms Table

    01–45 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) PROBLEM SYMPTOMS TABLE The suspected circuits or parts for each problem symptom are shown in the table below. Use this table to troubleshoot when, during a DTC check, a ”Normal” code is displayed but the problem is still occurring. Num- bers in the table show the inspection order in which the circuits or parts should be checked.
  • Page 46: Circuit Inspection

    01–46 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) CIRCUIT INSPECTION How to read and use each page is shown below. D Circuit Description D Inspection Procedures The major role, operation of the circuit and its Use the inspection procedures to determine component parts are explained.
  • Page 47: Handling Connectors

    When connecting a connector, press firmly until you hear the lock close with a ”click” sound. INCORRECT If checking the connector with a TOYOTA electrical tester, check it from the backside (harness side) of the connector using a mini test lead.
  • Page 48 01–48 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a fe- male terminal, and check for good tension when in- serting and after full engagement. Same terminal as a male terminal D25088...
  • Page 49 01–49 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) Check the resistance. Fig. 2 Disconnect connectors A and C and measure the resistance between them. Resistance: Below 1 Ω HINT: Sensor Measure the resistance while lightly shaking the wire harness vertically and horizontally.
  • Page 50 01–50 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) Example results: Tester Connection Specified Condition Connector A terminal 1 – Body ground Connector B terminal 1 – Body ground Connector C terminal 1 – Body ground If your results match the examples above, an open circuit exists in the wire harness between terminal 1 of B and terminal 1 of CHECK SHORT CIRCUIT Fig.
  • Page 51 01–51 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) Disconnect connector B and measure the resis- Fig. 7 tance between terminal 1 of connector A and the body ground, and terminal 1 of connector B2 and the body ground. Fig. 7: Sensor Tester Connection Specified Condition...
  • Page 52 01–52 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) TERMS 010S6–01 ABBREVIATIONS USED IN MANUAL Abbreviations Meaning Anti–Lock Brake System Air Conditioner Alternating Current Accessory ACIS Acoustic Control Induction System ACSD Automatic Cold Start Device A.D.D. Automatic Disconnecting Differential Air–Fuel Ratio Active Height Control Suspension Automatic Locking Retractor Alternator...
  • Page 53 01–53 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) Abbreviations Meaning Defogger Deflector DIFF. Differential DIFF. LOCK Differential Lock D/INJ Direct Injection Data Link Connector Distributorless Ignition DOHC Double Overhead Camshaft Dash Pot Dead Soak Digital Signal Processor Diagnostic Trouble Code Digital Versatile Disc Electric Brake Force Distribution ECAM...
  • Page 54 01–54 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) Abbreviations Meaning H–FUSE High Current Fuse High High Intensity Discharge (Head Lamp) Housing Hard Top Heated Windshield System Integrated Circuit Indirect Diesel Injection Independent Front Suspension Ignition Integrated Ignition Assembly Intake (Manifold, Valve) Intermittent Instrument Panel Independent Rear Suspension...
  • Page 55 Cold–Start Fuel Injection Switch System Transaxle TACH Tachometer Throttle Body Electronic Fuel Injection Turbocharger TCCS TOYOTA Computer–Controlled System Timing Control Valve Top Dead Center TEMP. Temperature TEMS TOYOTA Electronic Modulated Suspension 2004 Prius – Preliminary Release (RM1075U) Author : Date :...
  • Page 56 – 2004 Prius – Preliminary Release (RM1075U) Abbreviations Meaning TOYOTA Free–Tronic Total Information System For Vehicle Development Transmission TOYOTA Motor Corporation TMMK TOYOTA Motor Manufacturing Kentucky, Inc. TRAC Traction Control System TURBO Turbocharge Three–Way Catalyst Underdrive Undersize Vacuum Control Valve...
  • Page 57: Glossary Of Sae And Toyota Terms

    2004 Prius – Preliminary Release (RM1075U) 010S7–01 GLOSSARY OF SAE AND TOYOTA TERMS This glossary lists all SAE–J1930 terms and abbreviations used in this manual in compliance with SAE rec- ommendations, as well as their TOYOTA equivalents. TOYOTA TERMS SAE TERMS ABBREVIATIONS ( )––ABBREVIATIONS...
  • Page 58 01–58 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO Idle Air Control Idle Speed Control (ISC) Intake Air Temperature Intake or Inlet Air Temperature Ignition Control Module – Indirect Fuel Injection Indirect Injection (IDL) Inertia Fuel–Shutoff –...
  • Page 59 01–59 INTRODUCTION – 2004 Prius – Preliminary Release (RM1075U) Transmission Control Module Transmission ECU, ECT ECU Throttle Position Throttle Position Transmission Range – Bimetallic Vacuum Switching Valve (BVSV) Thermal Vacuum Valve Thermostatic Vacuum Switching Valve (TVSV) Three–Way Catalytic (TWC) Three–Way Catalytic Converter Manifold Converter TWC+OC Three–Way + Oxidation Catalytic Converter...

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