Toyota - Prius - Wiring Diagram - 2001 - 2001

FOREWORD This wiring diagram manual has been prepared to provide information on the electrical system of the 2001 PRIUS. Applicable models: NHW11 Series For service specifications and repair procedures of the above models other than those listed in this manual, refer to the following manuals; Manual Name
2001 PRIUS Repair Manual Volume 1 Volume 2
2001 PRUIS New Car Features Pub. No. RM778U1 RM778U2 NCF182U All information in this manual is based on the latest product information at the time of publication. However, specifications and procedures are subject to change without notice. CAUTION When repairing the hybrid vehicle (HV), always follow the direction given in the repair manual listed above to prevent electrical shock, leakage or explosion. NOTICE When handling supplemental restraint system components (removal, installation or inspection, etc.), always follow the direction given in the repair manuals listed above to prevent accidents and supplemental restraint system malfunction. 2001 PRIUS (EWD414U) A INTRODUCTION This manual consists of the following 13 sections: No. Section Description INDEX Index of the contents of this manual. INTRODUCTION Brief explanation of each section. B HOW TO USE THIS MANUAL Instructions on how to use this manual. C TROUBLE– SHOOTING Describes the basic inspection procedures for electrical circuits. D ABBREVIATIONS Defines the abbreviations used in this manual. E GLOSSARY OF TERMS AND SYMBOLS Defines the symbols and functions of major parts. F RELAY LOCATIONS Shows position of the Electronic Control Unit, Relays, Relay Block, etc. This section is closely related to the system circuit. G ELECTRICAL WIRING ROUTING Describes position of Parts Connectors, Splice points, Ground points, etc. This section is closely related to the system circuit. INDEX Index of the system circuits. SYSTEM CIRCUITS Electrical circuits of each system are shown from the power supply through ground points. Wiring connections and their positions are shown and classified by code according to the connection method. (Refer to the section, ”How to use this manual”). The ”System Outline” and ”Service Hints” useful for troubleshooting are also contained in this section. I GROUND POINT Shows ground positions of all parts described in this manual. J POWER SOURCE (Current Flow Chart) Describes power distribution from the power supply to various electrical loads. K CONNECTOR LIST Describes the form of the connectors for the parts appeared in this book. This section is closely related to the system circuit. L PART NUMBER OF CONNECTORS Indicates the part number of the connectors used in this manual. M OVERALL ELECTRICAL WIRING DIAGRAM Provides circuit diagrams showing the circuit connections. A H 2001 PRIUS (EWD414U) HOW TO USE THIS MANUAL B This manual provides information on the electrical circuits installed on vehicles by dividing them into a circuit for each system. The actual wiring of each system circuit is shown from the point where the power source is received from the battery as far as each ground point. (All circuit diagrams are shown with the switches in the OFF position.) When troubleshooting any problem, first understand the operation of the circuit where the problem was detected (see System Circuit section), the power source supplying power to that circuit (see Power Source section), and the ground points (see Ground Point section). See the System Outline to understand the circuit operation. When the circuit operation is understood, begin troubleshooting of the problem circuit to isolate the cause. Use Relay Location and Electrical Wiring Routing sections to find each part, junction block and wiring harness connectors, wiring harness and wiring harness connectors, splice points, and ground points of each system circuit. Internal wiring for each junction block is also provided for better understanding of connection within a junction block. Wiring related to each system is indicated in each system circuit by arrows (from__, to__). When overall connections are required, see the Overall Electrical Wiring Diagram at the end of this manual. 2001 PRIUS (EWD414U) B HOW TO USE THIS MANUAL ∗ The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION. [A] STOP LIGHT FROM POWER SOURCE SYSTEM (SEE PAGE 66) ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, [C] 15A STOP 7. 5A GAUGE 4 IB 2 1 ,,,, @@@@ €€€€ ÀÀÀÀ @@@@ €€€€ ÀÀÀÀ ,,,, @@@@ €€€€ ÀÀÀÀ ,,,, @@@@ €€€€ ÀÀÀÀ ,,,, @@@@ €€€€ ÀÀÀÀ ,,,, @@@@ €€€€ ÀÀÀÀ ,,,, @@@@ €€€€ ÀÀÀÀ ,,,, 7 3C [G] 15 3C R–L W–R R (W/G) 3 IB L (S/D) [B] R–L 4 2 C7 REAR LIGHTS WARNING LIGHT [COMB. METER] S6 STOP LIGHT SW 14 [E] IE1 13 1 G–W [D] L (S/D) I5 [F] G–W Y–G G–W TO ABS ECU [H] 7 L4 LIGHT FAILURE SENSOR 8 DELAY CIRCUIT [J] B18 H17 HIGH MOUNTED STOP LIGHT [L] 1 W–B B18 W–B 1 BV1 W–B W–B W–B 3 2 BO 50 [M] BL [N] 2001 PRIUS (EWD414U) W–B 4 [K] (SHIELDED) R6 STOP LIGHT RH [REAR COMB. LIGHT LH] R7 STOP LIGHT RH [REAR COMB. LIGHT RH] G–R G–R G–R 1 BV1 3 11 G [I] 4 1 G–R 2 4 B [I] [A] : System Title [B] : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: Indicates Relay Block No.1 : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black W = White BR = Brown L = Blue V SB = Sky Blue = Violet R = Red G = Green LG = Light Green [C] : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. P Y GR = Gray [D] : Indicates related system. The first letter indicates the basic wire color and the second letter indicates the color of the stripe. [E] : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows ( ). Outside numerals are pin numbers. = Pink = Yellow O = Orange Example: L–Y L (Blue) Female Male ( Y (Yellow) [J] : Indicates a wiring Splice Point (Codes are ”E” for the Engine Room, ”I” for the Instrument Panel, and ”B” for the Body). ) The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component’s location, e.g, ”E” for the Engine Compartment, ”I” for the Instrument Panel and Surrounding area, and ”B” for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. [F] : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. [G] : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. Example: ,,,, ,,,, 3C indicates ,,,, that it is inside ,,,, Junction Block ,,,, No.3 ,,,, ,,,, The Location of splice Point I 5 is indicated by the shaded section. [K] : Indicates a shielded cable. [L] : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order from upper left to lower right Female Numbered in order from upper right to lower left Male [M] : Indicates a ground point. [H] : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. The first letter of the code for each ground point(s) indicates the component’s location, e.g, ”E” for the Engine Compartment, ”I” for the Instrument Panel and Surrounding area, and ”B” for the Body and Surrounding area. [N] : Page No. 2001 PRIUS (EWD414U) B HOW TO USE THIS MANUAL [O] SYSTEM OUTLINE Current is applied at all times through the STOP fuse to TERMINAL 2 of the stop light SW. When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL 8 of the light failure sensor, and also flows through the rear lights warning light to TERMINAL 4 of the light failure sensor. STOP LIGHT DISCONNECTION WARNING When the ignition SW is turned on and the brake pedal is pressed (Stop light SW on), if the stop light circuit is open, the current flowing from TERMINAL 7 of the light failure sensor to TERMINALS 1, 2 changes, so the light failure sensor detects the disconnection and the warning circuit of the light failure sensor is activated. As a result, the current flows from TERMINAL 4 of the light failure sensor to TERMINAL 11 to GROUND and turns the rear lights warning light on. By pressing the brake pedal, the current flowing to TERMINAL 8 of the light failure sensor keeps the warning circuit on and holds the warning light on until the ignition SW is turned off. [P] SERVICE HINTS S6 STOP LIGHT SW 2–1 : Closed with the brake pedal depressed L4 LIGHT FAILURE SENSOR 1, 2, 7–GROUND : Approx. 12 volts with the stop light SW on 4, 8–GROUND : Approx. 12 volts with the ignition SW at ON position 11–GROUND : Always continuity [Q] : PARTS LOCATION Code See Page See Page Code See Page 34 L4 36 R7 37 H17 36 R6 37 S6 35 : RELAY BLOCKS [R] Code 1 [S] Code C7 @@@ €€€ ÀÀÀ ,,, ,,, @@@ €€€ ÀÀÀ ,,, @@@ €€€ ÀÀÀ Code See Page 18 Relay Blocks (Relay Block Location) R/B No.1 (Instrument Panel Left) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR See Page Junction Block and Wire Harness (Connector Location) IB 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 3C 22 Instrument Panel Wire and J/B No.3 (Instrument Panel Left Side) [T] : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IE1 42 Floor Wire and Instrument Panel Wire (Left Kick Panel) BV1 50 Luggage Room Wire and Floor Wire (Luggage Compartment Left) [U] : GROUND POINTS Code See Page Ground Points Location BL 50 Under the Left Quarter Pillar BO 50 Back Panel Center [V] : SPLICE POINTS Code I5 See Page 44 Wire Harness with Splice Points Cowl Wire Code B18 2001 PRIUS (EWD414U) See Page 50 Wire Harness with Splice Points Luggage Room Wire B [O] : Explains the system outline. [P] : Indicates values or explains the function for reference during troubleshooting. [Q] : Indicates the reference page showing the position on the vehicle of the parts in the system circuit. Example : Part ”L4” (Light Failure Sensor) is on page 36 of the manual. ∗ The letter in the code is from the first letter of the part, and the number indicates its order in parts starting with that letter. Example : L 4 Á Á Parts is 4th in order Light Failure Sensor [R] : Indicates the reference page showing the position on the vehicle of Relay Block Connectors in the system circuit. Example : Connector ”1” is described on page 18 of this manual and is installed on the left side of the instrument panel. [S] : Indicates the reference page showing the position on the vehicle of J/B and Wire Harness in the system circuit. Example : Connector ”3C” connects the Instrument Panel Wire and J/B No.3. It is described on page 22 of this manual, and is installed on the instrument panel left side. [T] : Indicates the reference page describing the wiring harness and wiring harness connector (the female wiring harness is shown first, followed by the male wiring harness). Example : Connector ”IE1” connects the floor wire (female) and Instrument panel wire (male). It is described on page 42 of this manual, and is installed on the left side kick panel. [U] : Indicates the reference page showing the position of the ground points on the vehicle. Example : Ground point ”BO” is described on page 50 of this manual and is installed on the back panel center. [V] : Indicates the reference page showing the position of the splice points on the vehicle. Example : Splice point ”I5” is on the Cowl Wire Harness and is described on page 44 of this manual. 2001 PRIUS (EWD414U) B HOW TO USE THIS MANUAL The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points ( EA , IB and IC shown below) can also be checked this way. I GROUND POINT FAN MAIN RELAY 5 A/C FAN RELAY NO.2 5 A/C FAN RELAY NO.3 5 E3 O/D MAIN SW E3 CLOCK W–B W–B A A A A E5 E6 W–B FRONT SIDE MARKER LIGHT RH W–B FRONT SIDE MARKER LIGHT LH W–B BRAKE FLUID LEVEL WARNING SW W–B W–B ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, W–B I4 W–B 2 IA1 B4 COMBINATION METER W–B 1 3D W–B CRUISE CONTROL MIRROR SW 3 3F W–B REMOTE CONTROL MIRROR SW 13 3G W–B TURN SIGNAL FLASHER 5 W–B 3E I2 REAR WINDOW DEFOGGER SW 6 3E I2 LIGHT CONTROL SW [COMB. SW] WIPER AND WASHER SW [COMB. SW] W–B I5 15 ID1 W–B W–B I5 W–B W–B BLOWER RESISTOR 8 IB1 W–B I8 W–B A/C AMPLIFIER 4 4 POWER WINDOW CONTROL RELAY B5 DOOR KEY LOCK SW LH B5 DOOR LOCK CONTROL SW FUEL CONTROL SW 3 IC3 I5 W–B WOOFER AMPLIFIER BR COMBINATION METER 4 BR BR 4 I3 BR I3 COMBINATION METER BR FUEL SENDER W–B 4 BR BR 5 BA1 W–B AUTO ANTENNA MOTOR B5 (4A–GZE) W–B HEATER RELAY POWER WINDOW MASTER SW I5 4 W–B BR B5 DOOR LOCK MOTOR LH W–B 4 RADIO AND PLAYER UNLOCK WARNING SW W–B W–B HORN SW [COMB. SW] DIMMER SW [COMB. SW] I2 W–B 10 EA2 I4 BLOWER SW I5 W–B B4 W–B I6 W–B EA ELECTRICAL IDLE−UP CUT RELAY (M/T) HEATER SERVO MOTOR AMPLIFIER PARKING BRAKE SW 7 W–B 3C E4 B4 I6 W–B 7 3B W–B DOOR LOCK MOTOR RH A E5 E4 W–B HEATER CONTROL ASSEMBLY J1 JUNCTION CONNECTOR W–B W–B W–B E4 W–B DOOR KEY LOCK SW RH A E2 E4 W–B W–B E3 W–B DOOR LOCK CONTROL SW RH DOOR LOCK CONTROL RELAY CIGARETTE LIGHTER E3 W–B RETRACT MOTOR LH PARKING LIGHT LH W–B W–B RETRACT MOTOR RH FRONT TURN SIGNAL LIGHT LH W–B W–B RETRACT CONTROL RELAY PARKING LIGHT RH W–B W–B RADIATOR FAN MOTOR FRONT TURN SIGNAL LIGHT RH W–B W–B 5 W–B FAN MAIN RELAY IB ∗ IC The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION. 2001 PRIUS (EWD414U) B The ”Current Flow Chart” section, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. J POWER SOURCE (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. 10A ECU–B Short Pin 2 2 7.5A DOME 15A EFI Battery 30A AM2 Fusible Link Block 2 10A HAZARD 6 2 20A RADIO NO.1 Starter S2 10A HORN 100A ALT 60A ABS 6 5 Engine Room R/B (See Page 20) Fuse 20A 10A System Page STOP ABS ABS and Traction Control Cruise Control Electronically Controlled Transmission and A/T Indicator Multiplex Communication System 194 187 180 166 210 DOME Cigarette Lighter and Clock Combination Meter Headlight Interior Light Key Reminder and Seat Belt Warning Light Auto Turn Off Theft Deterrent and Door Lock Control 214 230 112 122 POWER SOURCE 40A DOOR LOCK CB 1.25B FL MAIN W W W 2 2 7 EB1 W W B W B 1 7.5A DOME I2 50A MAIN E7 2 W–L W W W I2 1 1 R W I2 1 B W 1 W B 2 2 4 W–B 2 B 4 B B 2 3 2 4 1 2 1 W–B 2 2 3 3 2 B–W 1 G 15A TAIL 1 20A DEFOG B–Y 1 G W–R 1 B 2 1 4 I8 IGNITION SW B–W STARTER RELAY E7 8 IG1 3 ACC 2 1 IG2 B 2 1 TAIL RELAY INJECTION RELAY B–O E7 2 W 15A HAZ–RADIO AM1 2 6 EB1 W–R W–R 2 AM2 E7 7.5A AM2 B G–W W BATTERY 3 EA2 1 EA1 W–B 1 1 E6 15A RAD CIG B–Y 1 ∗ P–L 1 The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION. 2001 PRIUS (EWD414U) B HOW TO USE THIS MANUAL K CONNECTOR LIST [A] I14 I15 DARK GRAY GRAY 1 1 2 I16 J1 J2 BLACK 2 A A 1 2 A A A A B B D D A A B CC CD D A 6 7 8 [B] J3 J4 K1 K2 L1 1 2 1 2 DARK GRAY A A A A A A A A A B B DD A A B CC CDD L2 L3 L4 M1 M2 1 2 3 4 5 6 7 8 9 101112 1 2 3 45 6 78 M3 1 2 1 1 2 3 4 2 M4 [D] N1 GRAY 1 2 3 [C] BLACK GRAY 1 1 1 7 5 6 2 3 4 8 9 10 N2 O1 O2 GRAY BLACK DARK GRAY 1 1 1 2 [A] : Indicates connector to be connected to a part. (The numeral indicates the pin No.) [B] : Junction Connector Indicates a connector which is connected to a short terminal. Junction Connector Junction connector in this manual include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to a wire harness from a different part.) Wire harness sharing the same short terminal grouping have the same color. Same Color Short Terminal [C] : Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. [D] : Connector Color Connectors not indicated are milky white in color. 2001 PRIUS (EWD414U) B L PART NUMBER OF CONNECTORS Code A1 Part Name A/C Ambient Temp. Sensor Part Name Part Number Part Number Code 90980–11070 D4 Diode (Door Courtesy Light) 90980–11608 90980–10962 A2 A/C Condenser Fan Motor 90980–11237 D5 Diode (Key Off Operation) A3 A/C Condenser Fan Relay 90980–10940 D6 Diode (Luggage Compartment Light) 90980–11608 D7 Door Lock Control Relay 90980–10848 ÁÁ ÁÁ A4 [A] A5 A/C Triple Pressure SW (A/C Dual and Single Pressure SW) A/T Oil Temp. Sensor [B] ÁÁ ÁÁ 90980–10943 D8 Door Courtesy Light LH [C] 90980–11413 D9 Door Courtesy Light RH 90980–11148 A6 ABS Actuator 90980–11151 D10 Door Courtesy SW LH A7 ABS Actuator 90980–11009 D11 Door Courtesy SW RH A8 ABS Speed Sensor Front LH 90980–10941 D12 Door Courtesy SW Front LH A9 ABS Speed Sensor Front RH 90980–11002 D13 Door Courtesy SW Front RH A10 Airbag Sensor Front LH D14 Door Courtesy SW Rear LH A11 Airbag Sensor Front RH A12 Auto Antenna Motor 90980–11097 90980–11856 D15 Door Courtesy SW Rear RH 90980–11194 D16 Door Key Lock and Unlock SW LH 90980–11194 D17 Door Key Lock and Unlock SW RH 90980–11156 90980–11170 [A] : Part Code [B] : Part Name [C] : Part Number Toyota Part Number are indicated. Not all of the above part numbers of the connector are established for the supply. In case of ordering a connector or terminal with wire, please confirm in advance if there is supply for it using “Parts Catalog News” (published by Parts Engineering Administration Dept.). 2001 PRIUS (EWD414U) C TROUBLESHOOTING To Ignition SW IG Terminal Fuse [A] SW 1 Voltmeter [B] VOLTAGE CHECK (a) Establish conditions in which voltage is present at the check point. Example: [A] – Ignition SW on [B] – Ignition SW and SW 1 on [C] – Ignition SW, SW 1 and Relay on (SW 2 off) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Relay [C] Solenoid SW 2 CONTINUITY AND RESISTANCE CHECK (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Ohmmeter SW If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Ohmmeter Diode (c) Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting of the electrical circuit. Digital Type Analog Type 2001 PRIUS (EWD414U) C To Ignition SW IG Terminal Test Light Fuse Case Short [A] SW 1 Short [B] Disconnect Disconnect Light (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: [A] – Ignition SW on [B] – Ignition SW and SW 1 on [C] – Ignition SW, SW 1 and Relay on (Connect the Relay) and SW 2 off (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: Relay Short [C] Disconnect SW 2 FINDING A SHORT CIRCUIT (a) Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) (b) When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Solenoid DISCONNECTION OF MALE AND FEMALE CONNECTORS To pull apart the connectors, pull on the connector itself, not the wire harness. HINT : Check to see what kind of connector you are disconnecting before pulling apart. Pull Up Pull Up Press Down Press Down 2001 PRIUS (EWD414U) C TROUBLESHOOTING HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Reference: 1. PREPARE THE SPECIAL TOOL 10 3 1 HINT : To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. DISCONNECT CONNECTOR 1 Example: (Case 1) 0.2 (mm) Up Tool 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTICE: Do not remove the terminal retainer from connector body. Terminal Retainer [A] Terminal Retainer For Non–Waterproof Type Connector HINT : The needle insertion position varies according to the connector’s shape (number of terminals etc.), so check the position before inserting it. [Retainer at Full Lock Position] Stopper ”Case 1” Raise the terminal retainer up to the temporary lock position. Terminal Retainer [Retainer at Temporary Lock Position] Example: (Case 2) Secondary Locking Device ”Case 2” Open the secondary locking device. 2001 PRIUS (EWD414U) C Tool Tab Tab Example: (Case 1) [B] Terminal Retainer Tool [Male] Access Hole ( Mark) Tool For Waterproof Type Connector HINT : Terminal retainer color is different according to connector body. Example: Terminal Retainer Black or White Black or White Gray or White : Connector Body : Gray : Dark Gray : Black [Female] ”Case 1” Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (
Mark) and pull the terminal retainer up to the temporary lock position. HINT : The needle insertion position varies according to the connector’s shape (Number of terminals etc.), so check the position before inserting it. Retainer at Full Lock Position Retainer at Temporary Lock Position [Male] Example: (Case 2) [Female] ”Case 2” Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Tool Tool [Male] Press Down Press Down [Female] 2001 PRIUS (EWD414U) C TROUBLESHOOTING Push the terminal retainer down to the temporary lock position. Retainer at Full Lock Position Retainer at Temporary Lock Position [Male] [Female] (c) Release the locking lug from terminal and pull the terminal out from rear. Locking Lug Tool 4. INSTALL TERMINAL TO CONNECTOR (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR 2001 PRIUS (EWD414U) ABBREVIATIONS D ABBREVIATIONS The following abbreviations are used in this manual. ABS = Anti–Lock Brake System A/C = Air Conditioning COMB. = Combination DC = Direct Current ECU = Electronic Control Unit EMPS = Electric Motor Power Steering ESA = Electronic Spark Advance EVAP = Evaporative Emission HV = Hybrid Vehicle J/B = Junction Block LH = Left–Hand PTC = Positive Temperature Coefficient R/B = Relay Block RH = Right–Hand SFI = Sequential Multiport Fuel Injection SRS = Supplemental Restraint System SW = Switch TEMP. = Temperature VSV = Vacuum Switching Valve w/ = With w/o = Without ∗ The titles given inside the components are the names of the terminals (terminal codes) and are not treated as being abbreviations. 2001 PRIUS (EWD414U) E GLOSSARY OF TERMS AND SYMBOLS GROUND The point at which wiring attaches to the Body, thereby providing a return path for an electrical circuit; without a ground, current cannot flow. BATTERY Stores chemical energy and converts it into electrical energy. Provides DC current for the auto’s various electrical circuits. CAPACITOR (Condenser) A small holding unit for temporary storage of electrical voltage. CIGARETTE LIGHTER An electric resistance heating element. HEADLIGHTS Current flow causes a headlight 1. SINGLE filament to heat up and emit light. A FILAMENT headlight may have either a single (1) filament or a double (2) filament 2. DOUBLE FILAMENT CIRCUIT BREAKER Basically a reusable fuse, a circuit breaker will heat and open if too much current flows through it. Some units automatically reset when cool, others must be manually reset. HORN An electric device which sounds a loud audible signal. DIODE A semiconductor which allows current flow in only one direction. IGNITION COIL Converts low–voltage DC current into high–voltage ignition current for firing the spark plugs. DIODE, ZENER LIGHT Current flow through a filament causes the filament to heat up and emit light. A diode which allows current flow in one direction but blocks reverse flow only up to a specific voltage. Above that potential, it passes the excess voltage. This acts as a simple voltage regulator. PHOTODIODE The photodiode is a semiconductor which controls the current flow according to the amount of light. LED (LIGHT EMITTING DIODE) Upon current flow, these diodes emit light without producing the heat of a comparable light. DISTRIBUTOR, IIA Channels high–voltage current from the ignition coil to the individual spark plugs. METER, ANALOG Current flow activates a magnetic coil which causes a needle to move, thereby providing a relative display against a background calibration. FUSE METER, DIGITAL Current flow activates one or many LED’s, LCD’s, or fluorescent displays, which provide a relative or digital display. A thin metal strip which burns through when too much current flows through it, thereby stopping current flow and protecting a circuit from damage. FUEL FUSIBLE LINK (for Medium Current Fuse) (for High Current Fuse or Fusible Link) A heavy–gauge wire placed in high amperage circuits which burns through on overloads, thereby protecting the circuit. The numbers indicate the crosssection surface area of the wires. M 2001 PRIUS (EWD414U) MOTOR A power unit which converts electrical energy into mechanical energy, especially rotary motion. E RELAY Basically, an electrically operated 1. NORMALLY switch which may be normally CLOSED closed (1) or open (2). Current flow through a small coil creates a magnetic field which either opens or closes an attached switch. SPEAKER An electromechanical device which creates sound waves from current flow. 2. NORMALLY OPEN SWITCH, MANUAL 1. NORMALLY OPEN RELAY, DOUBLE THROW A relay which passes current through one set of contacts or the other. Opens and closes circuits, i it thereby th b stopping (1) or allowing (2) current flow. 2. NORMALLY CLOSED RESISTOR An electrical component with a fixed resistance, placed in a circuit to reduce voltage to a specific value. SWITCH, DOUBLE THROW A switch which continuously passes current through one set of contacts or the other. RESISTOR, TAPPED A resistor which supplies two or more different non adjustable resistance values. SWITCH, IGNITION A key operated switch with several positions which allows various circuits, particularly the primary ignition circuit, to become operational. RESISTOR, VARIABLE or RHEOSTAT A controllable resistor with a variable rate of resistance. Also called a potentiometer or rheostat. SENSOR (Thermistor) A resistor which varies its resistance with temperature. SWITCH, WIPER PARK Automatically returns wipers to the stop position when the wiper switch is turned off. SENSOR, SPEED Uses magnetic impulses to open and close a switch to create a signal for activation of other components. TRANSISTOR A solidstate device typically used as an electronic relay; stops or passes current depending on the voltage applied at ”base”. (Reed Switch Type) SHORT PIN Used to provide an unbroken connection within a junction block. SOLENOID An electromagnetic coil which forms a magnetic field when current flows, to move a plunger, etc. 2001 PRIUS (EWD414U) WIRES Wires are always drawn as (1) NOT straight lines on wiring CONNECTED diagrams. Crossed wires (1) without a black dot at the junction are j nott joined; j i d crossed wires (2) with a black dot or octagonal ( ) (2) SPLICED mark at the junction are spliced (joined) connections. F RELAY LOCATIONS [Engine Compartment] [Instrument Panel] 2001 PRIUS (EWD414U) F [Body] 2001 PRIUS (EWD414U) F RELAY LOCATIONS Fusible Link Block No.1 Engine Compartment Left (See Page 20) 2001 PRIUS (EWD414U) F Fusible Link Block No.2 2 Luggage Room Left (See Page 21) : Engine Room R/B No.2 Right Side of Reserve Tank (See Page 20) 2001 PRIUS (EWD414U) F RELAY LOCATIONS 3 : Engine Room R/B No.3 Engine Compartment Right (See Page 20) 2001 PRIUS (EWD414U) MEMO 2001 PRIUS (EWD414U) F RELAY LOCATIONS ,,, ,,, ,,,: Engine Room J/B Engine Compartment Left (See Page 20) 2001 PRIUS (EWD414U) F 2001 PRIUS (EWD414U) F RELAY LOCATIONS [Engine Room J/B Inner Circuit] 2001 PRIUS (EWD414U) F 2001 PRIUS (EWD414U) F RELAY LOCATIONS ,,, ,,, ,,,: Instrument Panel J/B Cowl Side Panel LH (See Page 20) 2001 PRIUS (EWD414U) F 2001 PRIUS (EWD414U) F RELAY LOCATIONS [Instrument Panel J/B Inner Circuit] 2001 PRIUS (EWD414U) F 2001 PRIUS (EWD414U) G ELECTRICAL WIRING ROUTING Position of Parts in Engine Compartment A 1 A/C Condenser Fan Motor A 2 A/C Magnetic Clutch and Lock Sensor A 3 A/C Triple Pressure SW (A/C Dual and Single Pressure SW) A 4 ABS Speed Sensor Front LH A 5 ABS Speed Sensor Front RH A 6 Ambient Temp. Sensor B B B B 1 2 3 4 Brake Actuator Brake Actuator Brake Actuator Brake Fluid Level Warning SW C C C C C C 1 2 3 4 5 6 Camshaft Position Sensor Camshaft Timing Oil Control Valve Circuit Breaker Sensor Converter Converter Crankshaft Position Sensor F 1 F 2 F 3 F 4 F 5 F 6 F 7 F 8 F 9 F 10 F 11 F 12 F 13 Front Airbag Sensor LH Front Airbag Sensor RH Front Parking Light LH Front Parking Light RH Front Side Marker Light LH Front Side Marker Light RH Front Turn Signal Light LH Front Turn Signal Light RH Front Wiper Motor Fusible Link Block No.1 Fusible Link Block No.1 Fusible Link Block No.1 Fusible Link Block No.1 H H H H H H Headlight LH Headlight RH Heated Oxygen Sensor (Bank 1 Sensor1) Horn Hydraulic Booster Hydraulic Booster 1 2 3 4 5 6 D 1 DC Motor E 1 Engine Coolant Temp. Sensor E 2 Engine Hood Courtesy SW 2001 PRIUS (EWD414U) G Position of Parts in Engine Compartment I I I I I I I I I I I I I I 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Ignition Coil and Igniter No.1 Ignition Coil and Igniter No.2 Ignition Coil and Igniter No.3 Ignition Coil and Igniter No.4 Injector No.1 Injector No.2 Injector No.3 Injector No.4 Inverter Inverter Inverter Inverter Inverter Inverter N 1 Noise Filter (Ignition) O 1 Oil Pressure SW R 1 Radiator Fan Motor S 1 Steering Shaft Torque Sensor T 1 Theft Deterrent Horn T 2 Throttle Control Motor T 3 Throttle Position Sensor V 1 Vacuum Sensor (HC Adsorber and Catalyst System) V 2 VSV (EVAP) V 3 VSV (HC Adsorber and Catalyst System) K 1 Knock Sensor M M M M 1 2 3 4 Mass Air Flow Meter Motor Generator No.1 Motor Generator No.2 Motor Generator No.2 W W W W 1 2 3 4 Washer Motor Water Pump Motor (A/C) Water Pump Motor (Inverter) Water Temp. SW 2001 PRIUS (EWD414U) G ELECTRICAL WIRING ROUTING Position of Parts in Instrument Panel A 7 A 8 A 9 A 10 A 11 A 12 A 13 A 14 A 15 A 16 A 17 A 18 A 19 A 20 A 21 A 22 A/C Amplifier A/C Amplifier A/C Amplifier A/C Room Temp. Sensor A/C Solar Sensor A/C Thermistor Accel Position Sensor Air Inlet Control Servo Motor Air Mix Control Servo Motor Air Vent Mode Control Servo Motor Airbag Sensor Assembly Airbag Sensor Assembly Airbag Sensor Assembly Airbag Squib (Front Passenger Airbag Assembly) Airbag Squib (Steering Wheel Pad) Ashtray Illumination B 5 B 6 B 7 B 8 B 9 B 10 B 11 B 12 B 13 B 14 Back–Up Light Relay Blower Motor Blower Motor Linear Controller Body ECU Body ECU Brake ECU Brake ECU Brake ECU Brake ECU Brake Warning Buzzer C 7 C 8 C 9 C10 C 11 C12 C13 C14 Center Cluster SW Cigarette Lighter Cigarette Lighter Illumination Combination Meter Combination Meter Combination SW Combination SW Combination SW D D D D Data Link Connector 3 Daytime Running Light Relay Diode (Door Courtesy) Diode (Daytime Running Light) 2 3 4 5 E 3 E 4 E 5 E 6 E 7 E 8 E 9 E 10 EMPS ECU EMPS ECU EMPS ECU EMPS ECU Engine Control Module Engine Control Module Engine Control Module Engine Control Module 2001 PRIUS (EWD414U) G Position of Parts in Instrument Panel G 1 Gateway ECU H 7 H 8 H 9 H10 H 11 H12 H13 H14 Hazard Warning SW Hazard Warning SW Heated Oxygen Sensor (Bank 1 Sensor 2) Hybrid Vehicle Control ECU Hybrid Vehicle Control ECU Hybrid Vehicle Control ECU Hybrid Vehicle Control ECU Hybrid Vehicle Control ECU I 15 Ignition SW J 1 J 2 J 3 J 4 J 5 J 6 J 7 J 8 J 9 J 10 J 11 J 12 J 13 J 14 J 15 J 16 J 17 J 18 J 19 J 20 J 21 Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector J 22 J 23 J 24 J 25 J 26 J 27 J 28 J 29 Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector L 1 Light Control Rheostat M 5 Multi Display M 6 Multi Display M 7 Multi Display P P P P 1 2 3 4 Park/Neutral Position SW Parking Brake SW PTC Heater PTC Heater R R R R 2 3 4 5 Radio and Player Radio and Player Radio and Player Remote Control Mirror SW S 2 Shift Lock ECU S 3 Stop Light SW T 4 Transponder Key Computer T 5 Turn Signal Flasher Relay U 1 Unlock Warning SW and Key Interlock Solenoid W 5 Wireless Door Control Receiver 2001 PRIUS (EWD414U) G ELECTRICAL WIRING ROUTING Position of Parts in Body A 23 ABS Speed Sensor Rear LH A 24 ABS Speed Sensor Rear RH B 15 B 16 B 17 B 18 B 19 B 20 B 21 D 6 D 7 D 8 D 9 D10 D 11 F 14 F 15 F 16 F 17 F 18 Battery Blower Motor Battery Blower Motor Controller Battery ECU Battery ECU Battery Fan Relay Buckle SW and Tension Reducer LH Buckle SW RH and Seat Belt Warning Occupant Detection Sensor Front Door Speaker LH Front Door Speaker RH Fuel Pump and Fuel Sender Fusible Link Block No.2 Fusible Link Block No.2 H15 High Mounted Stop Light H16 Hybrid Vehicle Battery H17 Hybrid Vehicle Battery I 16 Interior Light I 17 Interlock SW Door Courtesy SW Front LH Door Courtesy SW Front RH Door Courtesy SW Rear LH Door Courtesy SW Rear RH Door Lock Control SW Front RH Door Lock Motor and Door Unlock Detection SW Rear LH D12 Door Lock Motor and Door Unlock Detection SW Rear RH D13 Door Lock Motor, Door Key Lock and Unlock SW and Door Unlock Detection SW Front LH D14 Door Lock Motor, Door Key Lock and Unlock SW and Door Unlock Detection SW Front RH J 30 J 31 J 32 J 33 Junction Connector Junction Connector Junction Connector Junction Connector L L L L L License Plate Light LH License Plate Light RH Luggage Compartment Door Unlock SW Luggage Compartment Light Luggage Compartment Light SW 2 3 4 5 6 2001 PRIUS (EWD414U) G Position of Parts in Body N 2 Navigation ECU N 3 Navigation ECU N 4 Noise Filter (Rear Window Defogger) P 5 P 6 P 7 P 8 P 9 P 10 P 11 P 12 P 13 P 14 P 15 Personal Light Power Window Control SW Front RH Power Window Control SW Rear LH Power Window Control SW Rear RH Power Window Master SW Power Window Motor Front LH Power Window Motor Front RH Power Window Motor Rear LH Power Window Motor Rear RH Pretensioner LH Pretensioner RH R 6 R 7 R 8 R 9 R10 R 11 Rear Combination Light LH Rear Combination Light RH Rear Speaker LH Rear Speaker RH Remote Control Mirror LH Remote Control Mirror RH S 4 S 5 S 6 S 7 S 8 S 9 S 10 S 11 S 12 Side Airbag Sensor LH Side Airbag Sensor RH Side Airbag Squib LH Side Airbag Squib RH System Main Relay System Main Relay System Main Relay System Main Relay System Main Relay T 6 Tension Reducer Solenoid V 4 Vapor Pressure Sensor V 5 VSV (Canister Closed Valve) V 6 VSV (Parge Flow Switching Valve) 2001 PRIUS (EWD414U) G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Ground Points : Location of Splice Points 2001 PRIUS (EWD414U) G Connector Joining Wire Harness and Wire Harness EA1 DARK GRAY 1 1 Code Joining Wire Harness and Wire Harness (Connector Location) EA1 Engine Wire and Engine No.4 Wire (Near the Radiator Fan) 2001 PRIUS (EWD414U) G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Ground Points 2001 PRIUS (EWD414U) G Connector Joining Wire Harness and Wire Harness Code IA1 IA2 Joining Wire Harness and Wire Harness (Connector Location) Engine Room Main Wire and Cowl Wire (Cowl Side Panel LH) IB1 Floor Wire and Cowl Wire (Cowl Side Panel LH) IC1 Front Door LH Wire and Cowl Wire (Left Kick Panel) ID1 ID2 IE1 IF1 IF2 Instrument Panel Wire and Cowl Wire (Left Kick Panel) Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) Instrument Panel Wire and Floor Wire (Left Kick Panel) IG1 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) IH1 Floor Wire and Engine Room Main Wire (Left Kick Panel) 2001 PRIUS (EWD414U) G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Splice Points 2001 PRIUS (EWD414U) G Connector Joining Wire Harness and Wire Harness Code II1 IJ1 IJ2 Joining Wire Harness and Wire Harness (Connector Location) Instrument Panel Wire and A/C Sub Wire (Instrument Panel Brace LH) Floor No.3 No 3 Wire and Instrument Panel Wire (Under the Instrument Panel Center) IK1 Engine Wire and Engine Room Main Wire (Right Kick Panel) IL1 Instrument Panel Wire and Engine Room Main Wire (Right Kick Panel) IM1 Engine Room Main Wire and Cowl Wire (Right Kick Panel) IN1 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IO1 Engine Wire and Cowl Wire (Right Kick Panel) IP1 Instrument Panel Wire and Cowl Wire (Right Kick Panel) IQ1 Front Door RH Wire and Cowl Wire (Right Kick Panel) 2001 PRIUS (EWD414U) G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Ground Points : Location of Splice Points 2001 PRIUS (EWD414U) G Connector Joining Wire Harness and Wire Harness BA1 BB1 GRAY 1 2 3 4 5 6 7 8 9 10 5 4 3 2 1 10 9 8 7 6 1 2 3 4 5 6 7 8 9 10 BC1 1 2 3 4 5 6 7 8 4 3 2 1 8 7 6 5 Code Joining Wire Harness and Wire Harness (Connector Location) BA1 Rear Door No.2 Wire and Floor Wire (Center Pillar LH) BB1 Rear Door No.1 Wire and Cowl Wire (Center Pillar RH) BC1 Cowl Wire and Fuel Tank Wire (Near the Fuel Tank) 2001 PRIUS (EWD414U) 5 4 3 2 1 10 9 8 7 6 POWER SOURCE W 50A HTR TO CONVERTER 1 2 30A RDI 1 2 30A CDS FAN 3 1B W 40A ABS NO. 1 1 3 W–R W W W 2 50A EMPS 1 1 B 2 3 1 A B–R 1 D F12 C , F13 D 100A DC/DC G 3 W–R 1 2G 2 2C 15A EFI B 2 9 1J 10A HORN FUSIBLE LINK BLOCK NO. 1 F10 A , F11 B 1 15A AM2 2 1B 50A HTR3 30A HTR2 1 2 3 G–W 10A TURN–HAZ 30A HTR1 1 1 C 15A DOME 2 3 B–R 15A THRO B B 10A ABS NO. 4 B–G 1 2 3 10A BATT FAN L 30A ABS NO. 2 1 20A HV 1 1B 1 B 5A DC/DC–S 2 20A ABS NO. 3 SHORT PIN 2 A 2 1 HEAD RELAY (*1) B–R 1 120A MAIN SHORT PIN 2 4 1 F17 A , F18 B FUSIBLE LINK BLOCK NO. 2 1 (* 1) 30A HEAD 2 4 3 (*2) TO CONVERTER W 3 10A HEAD LO (RH) SHORT PIN 5 (* 2) 1 (* 2) 10A HEAD LO (LH) 1 10A HEAD HI (LH) 2 BATTERY 4 10A HEAD HI (RH) 3 DIM RELAY 7. 5A DRL 11 1J R 3 2001 PRIUS (EWD414U) 1 2 3 R–L W–R W W 1 2H 1 * 1 : W/O DAYTIME RUNNING LIGHT * 2 : W/ DAYTIME RUNNING LIGHT 2 30A POWER 10A SRS ACC 30A DOOR 40A DEF W–G 3 2B 5A AM1 15A CIG ACC RELAY I15 IGNITION SW ACC 3 P–L 2 AM1 8 2C 5 3 1 2 7 AM2 2 15A STOP 20A PWR1 IG1 4 B–Y ST1 W–R 10A ACC 1 IG2 6 B–W IG1 RELAY 6 2D 5 3 1 2 10A HTR 7. 5A ECU–B 10A GAUGE 7. 5A OBDII ST2 8 R–W 30A WIPER 5A ECU–IG 15A WASHER TAIL RELAY 5 3 1 2 10A HEAD (RH) 10A HEAD (LH) 2001 PRIUS (EWD414U) 5A PANEL 7. 5A TAIL POWER SOURCE SERVICE HINTS HEAD RELAY 2–1 : Closed with the light control SW at HEAD position or the dimmer SW at FLASH position Closed with the engine running and the parking brake pedal released (Parking brake SW off) [w/ Daytime running light] TAIL RELAY 5–3 : Closed with the light control SW at TAIL or HEAD position I15 IGNITION SW 2–3 : Closed with the ignition key at ACC or ON position 2–4 : Closed with the ignition key at ON or ST position 7–6 : Closed with the ignition key at ON or ST position 7–8 : Closed with the ignition key at ST position : PARTS LOCATION Code F10 See Page Code See Page A 34 F13 D 34 F11 B 34 F17 A 38 F12 C 34 F18 B 38 Code I15 : RELAY BLOCKS Code 3 See Page 24 Relay Blocks (Relay Block Location) Engine Room R/B No.3 (Engine Compartment Right) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1B 1J See Page Junction Block and Wire Harness (Connector Location) 27 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl ( Side Panel LH)) 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) 2B 2C 2D 2G 2H 2001 PRIUS (EWD414U) See Page 37 MEMO 2001 PRIUS (EWD414U) TOYOTA HYBRID SYSTEM H10 C , H11 A , H12 B , H13 E , H14 D HYBRID VEHICLE CONTROL ECU ST2 STP 1 D CCS 16 D GND1 31 D GND2 24 D IG2 6 B–W ST2 8 R–W B–W 9 1J 3 1J C A 3 B–W W–R 11 2G C A 15A AM2 W–B W–B L 6 ID1 5 L B B B–W 1 2G J24 A , J25 B 5 2B I15 IGNITION SW JUNCTION CONNECTOR 2 2C B–W 4 FROM STOP LIGHT SW W–R 7 AM2 S3 STOP LIGHT SW B–W G–W R–W 2 D B–Y ST1– 7 E B–W IGSW 6 E 1 B–W IG2 RELAY 5 3 2 CCS CRUISE 2 1B 2 1A 3 1K W–B B–W RES/ACC 1 ECC 4 C14 CRUISE CONTROL SW [COMB. SW] B–G W–B 1 D M CANCEL W–B FUSIBLE LINK BLOCK NO. 1 2 W–B F12 C , F13 D W–B 1 C SET/COAST W3 WATER PUMP MOTOR (INVERTER) B–W B 14 IK1 A B A B A B E5 F18 FUSIBLE LINK BLOCK NO. 2 W–B J18 A , J19 B JUNCTION CONNECTOR W–B A A A A W–B 120A MAIN 1 W–B W–B BATTERY A IG 2001 PRIUS (EWD414U) J17 JUNCTION CONNECTOR * 1 : SHIELDED H10 C , H11 A , H12 B , H13 E , H14 D N D B R 14 D 12 D 23 D 15 D 22 D 15 E 13 E 23 E 22 E 14 E 12 E 11 E 21 E G L B W R L–R L–W L–B LG–R R–B W B R VPA1 EP1 VCP2 VPA2 EP2 VSFT SFT GSFT EOM 5 E J21 JUNCTION CONNECTOR VCP1 W–B P 13 D Y HYBRID VEHICLE CONTROL ECU E E W–B (*1) (*1) W–B I4 W B R 6 7 4 9 8 3 B 1 P1 PARK/NEUTRAL POSITION SW E A E A W–B W–B A13 ACCEL POSITION SENSOR D B W–B R–B 5 W–B LG–R 2 J22 A , J23 B L–B 1 EP2 JUNCTION CONNECTOR L–W 2 VPA2 W–B L–R 4 VCP2 W 3 EP1 L 5 VPA1 G 6 VCP1 Y R I2 A B J24 A , J25 B JUNCTION CONNECTOR A A A A W–B W–B W–B 8 2D W–B 8 2K W–B W–B J11 JUNCTION CONNECTOR A ID 2001 PRIUS (EWD414U) TOYOTA HYBRID SYSTEM H10 C , H11 A , H12 B , H13 E , H14 D HYBRID VEHICLE CONTROL ECU MSN 13 C R MSNG 20 C G GMT 1 C B–R GMTG 8 C G–W GCSG 12 C BR GCS 5 C Y W GRFG 17 C B GRF 10 C (* 1) R GSN 4 C G GSNG 11 C (* 1) (* 1) (*1) W–B I8 (*1) G R B W Y BR G–W B–R G R W–B I8 7 A 2 A 1 A 6 A 3 A 8 A 9 A 4 A 5 B 2 B GSN GRF GRFG GCS GCSG GMTG GMT MSNG MSN W–B GSNG 3 1K M2 A MOTOR GENERATOR NO. 1 M3 B , M4 C MOTOR GENERATOR NO. 2 W–B W–B W–B 1 1A B A B A B A J8 A , J9 B C B C B W–B W–B JUNCTION CONNECTOR W–B W–B W–B W–B W–B 2001 PRIUS (EWD414U) * 1 : SHIELDED H10 C , H11 A , H12 B , H13 E , H14 D HYBRID VEHICLE CONTROL ECU GO 10 B G 6 D O SPDO 8 D R–Y ESTP 29 D BR HTE– 19 D Y HTE+ 27 D L ETH– 28 D P ETH+ (* 1) GR MMT 2 C R–W MMTG 9 C W MRFG 18 C B MRF 19 C (*1) L MCSG 21 C P MCS 14 C 9 IA2 (*1) R–Y O G SPHV GO MPX2 J18 JUNCTION CONNECTOR B 11 MPD2 W–B MPD1 MPX+ MPX+ GR–B A7 A/C AMPLIFIER GR–B 4 MPX– 15 4 MP2+ 16 B8 BODY ECU B GR B M3 B , M4 C MOTOR GENERATOR NO. 2 ESTP 13 D G1 GATEWAY ECU MMT 21 C GR–L 1 C MMTG 10 C MPX1 (* 1) GR 3 C MRFG MRF 16 C HTE– 14 D (* 1) R–W 1 B MCSG 18 C HTE+ ENGINE CONTROL MODULE W–B W 4 B B P L 6 B 19 C E 9 C , E10 D I8 MCS ETH– BR 27 C Y L 28 C ETH+ 3 B (*1) P (* 1) (*1) W–B I8 GR 11 GR–B GR W–B W–B W–B W–B W–B W–B A W–B J17 JUNCTION CONNECTOR IG 2001 PRIUS (EWD414U) TOYOTA HYBRID SYSTEM H10 C , H11 A , H12 B , H13 E , H14 D HYBRID VEHICLE CONTROL ECU GIWA 28 A R GIWB 18 A G GIVB 8 A W GIVA 19 A B R MIWA 25 A Y VB 20 A G MIWB 17 A W MIVB 7 A (*1) (* 1) (* 1) G MIVA 16 A B MIVG 26 A B MVU 5 A W MUU 4 A R MWU 6 A G MIT 11 A L MSDN 13 A Y MSIV 21 A G R W B B W G Y R B W G R 4 D M–SDOWN L 7 C M–SINV Y G (*1) 5 D 3 D 1 D 2 D 6 D 1 C 3 C 4 C 5 C 2 C 1 B 3 B 4 B 2 B M–INVT M–WU M–UU M–VU M–GINV M–IVA M–IVB M–IWB I 9 D , I10 C , I11 A , I12 B , VB I13 E , M–IWA G–IVA G–IVB G–IWB G–IWA I14 F INVERTER GND (* 1) (* 1) (* 1) A A A A A A A W–B W–B W–B W–B (* 1) 6 B J7 JUNCTION CONNECTOR GR–B GR–B GR GR W–B W–B W–B A W–B A J1 JUNCTION CONNECTOR A IE W–B EC 2001 PRIUS (EWD414U) H10 C , H11 A , H12 B , H13 E , H14 D HYBRID VEHICLE CONTROL ECU 5A DC/DC–S F10 FUSIBLE LINK BLOCK NO. 1 1 1 F17 FUSIBLE LINK BLOCK NO. 2 W–G 12 IA1 100A DC/DC IF1 2 I9 W–G 13 IA1 W–G W–G W–G W B–R 2 V–R I17 INTERLOCK SW +B2 5 D W–G FROM POWER SOURCE SYSTEM (SEE PAGE 50) O 10 +B1 4 D W–G L–O NODD 4 B O ILK 4 E B GFIV 24 A G GSIV 15 A B MFIV 14 A B GIVG 27 A R GUU 1 A W GVU 2 A G GWU 3 A L G1T 23 A Y GSDN 12 A (* 1) I9 D , 8 C 7 B 8 B 6 C 4 A M–FINV G–SINV G–FINV CVRSW NODD I10 C , I11 A , I12 B , I13 E , B–R 6 A G–UU G–GINV L–O 1 A G–VU 2 IH1 V–R B 2 A B R 3 A G W 5 A G–INVT G–WU B G 4 A G–SDOWN L Y 4 IH1 3 A 1 B AMD S 1 A IGCT C4 A , C5 B I14 F CONVERTER INVERTER * 1 : SHIELDED * 2 : HIGH VOLTAGE (273. 6V) IDH 2 A Y IGCT 5 B (* 2) O 1 E (* 2) O 1 F CBI W–G CEI Y 14 IE1 O(* 2) O(* 2) GR–B GR GR Y GR–B IDH 10 2001 PRIUS (EWD414U) A7 A/C AMPLIFIER TOYOTA HYBRID SYSTEM H10 C , H11 A , H12 B , H13 E , H14 D HYBRID VEHICLE CONTROL ECU SPDI 25 D B–L V–W FROM POWER SOURCE SYSTEM (SEE PAGE 50) 1B 26 D R–W GB 8 B 15A DOME 19 IE1 V–W 10A GAUGE G A 7 1J V–W J27 A , J28 B L–Y 5 2A W–G G B JUNCTION CONNECTOR W–G W–G C10 A , C11 B COMBINATION METER 14 A 2 B 3 B L GR–B GR 10 IB1 6 IB1 B–L 1 IH1 R–W 13 A CHARGE 21 A W–R 6 2A CRUISE 4 2A OUTPUT CONTROL 7 2B L 22 A 2 2G L L I9 O(* 2) O(* 2) O(* 2) O(* 2) GR–B GR L W–B W–R R–W B–L 7 2A 2 A 17 A 16 A 6 2B IH W–B W–B BR 22 A B17 A , B18 B BJ BATTERY ECU 2001 PRIUS (EWD414U) H10 C , H11 A , H12 B , H13 E , H14 D HYBRID VEHICLE CONTROL ECU CON1 GR 8 IH1 9 IH1 1 E 11 IF1 P G R B CON3 2 B (* 1) * 1 : SHIELDED * 2 : HIGH VOLTAGE (273. 6V) W CON2 13 B P DTH– 18 E GR DTH+ 19 E V HTD– 20 E V HTD+ 2 E 5 A 1 A 1 B 1 C 7 A 2 A 6 A Y–R 4 A Y–B 3 A Y IF2 O(* 2) 5 O(* 2) IF2 W–B 3 SYSTEM MAIN RELAY IF2 (* 1) 4 G IF2 R 2 B IF2 W 1 S 8 A , S 9 B , S10 C W–G S11 D , S12 E W–G 1 D 1 E O(* 2) O(* 2) B2 B B B B J32 A , J33 B C A JUNCTION CONNECTOR W–B C A W–B W–B W–B W–B O(* 2) O(* 2) W B R G Y Y–B Y–R W–B 6 A 7 A 18 A 19 A 4 B 10 B 3 B B17 A , B18 B BATTERY ECU 2001 PRIUS (EWD414U) TOYOTA HYBRID SYSTEM H10 C , H11 A , H12 B , H13 E , H14 D HYBRID VEHICLE CONTROL ECU BTH– G R 16 14 22 HVI+ 2 HVI– TC SIL 10 E 10 D 21 D W–L V 24 HAI 9 E C E J16 JUNCTION CONNECTOR C HVO+ HVO– B11 BRAKE ECU 10 ID1 E W–L LG 1 HAO 9 D P–B WFSE 17 D P–B BTH+ 18 D Y–R HTB– 30 D G–R C3 CIRCUIT BREAKER SENSOR G–R BR–B 20 D Y HTB+ AS1 15 B P AS1G 14 B 2 ID1 1 ID1 W–G W P–B W–G W E J26 JUNCTION CONNECTOR W Y Y–R P–B 15 12 8 13 WFSE OP2 OP3 W P E D2 DATA LINK CONNECTOR 3 7 TC SIL O(* 2) O(* 2) O H16 A , H17 B HYBRID VEHICLE BATTERY 1 A (* 2) O W–B (* 2) W–B 1 B SERVICE PLUG O O (* 2) (*2) O LG–B L–O LG P Y–B L–W L LG–R Y P–L G L–R G–W R W L–B L L B B W BUSBER MODULE GR BUSBER MODULE SENSOR V–Y HYBRID VEHICLE BATTERY GR–B HYBRID VEHICLE BATTERY 14 2 15 3 16 4 17 5 18 6 7 20 8 21 9 22 10 23 11 24 1 2 3 4 5 B17 A , B18 B BATTERY ECU 2001 PRIUS (EWD414U) FROM POWER SOURCE SYSTEM (SEE PAGE 50) H10 C , H11 A , H12 B , H13 E , H14 D HYBRID VEHICLE CONTROL ECU FCVC 7 D 20A HV MREL 3 D 11 1F L–R G–Y IA1 7 IH1 G–Y 8 HEVC T4 TRANSPONDER KEY COMPUTER A18 AIRBAG SENSOR ASSEMBLY GSW2 8 1J O B–W L 4 23 10A BATT FAN 7 B G–Y 3 E BATT L–R ABFS LG–R W–G 2 2 5 L 5 2 G–Y 2 3 W–B IGCT RELAY 3 B15 BATTERY BLOWER MOTOR IF1 2 G–Y G–Y B A W–B 3 J3 B B A J2 A , C B W B B JUNCTION CONNECTOR 1 A A G–Y A A JUNCTION CONNECTOR J22 A , J23 B W 2 1 L W B19 BATTERY FAN RELAY W 1 M 2 L–B W–B L L–B W–G H16 A , H17 B L–B 8 B 9 B 2 B B W–B B B17 A , B18 B BI BATTERY ECU 2001 PRIUS (EWD414U) J32 JUNCTION CONNECTOR L–R 1 A A W–B LG–R 8 A G–Y W 10 J7 JUNCTION CONNECTOR W–B W–B 1 G R R W G 9 L–B 2 * 2 : HIGH VOLTAGE (273. 6V) 8 4 A J1 JUNCTION CONNECTOR W–B 5 IH1 7 3 B16 BATTERY MOTOR BLOWER CONTROLLER SENSOR 6 L W G–Y HYBRID VEHICLE BATTERY A IE TOYOTA HYBRID SYSTEM SYSTEM OUTLINE FEATURES OF TOYOTA HYBRID SYSTEM This system controls the following modes in order to achieve the most efficient operations to match the driving conditions. (1) Supply of electrical power from the HV battery to motor generator no.2 provides force to drive the wheels. (2) While the tires are driven by the engine via the planetary gears, motor generator no.1 is driven via the planetary gears to supply electricity to motor generator no.2 to drive the wheels. (3) When the vehicle is decelerating, kinetic energy from the wheels is recovered and converted into electrical energy and used to recharge the HV battery by means of motor generator no.2. The hybrid vehicle control ECU switches between these modes (1, 2, 1+2, or 3) according to the driving conditions. However, when the state of charge of the HV battery is low, the HV battery is charged by the engine by turning motor generator no.1. CRUISE CONTROL OPERATION Cruise control is the speed control device, which sets the desired speed by just operating the switch on the control panel without pressing the accelerator pedal. This device is used when you would like to drive the vehicle at the fixed speed. 1. SET CONTROL If you operate the SET/COAST switch when driving (The available range of set speed: between about 40 and 200 km/h) with the main switch is ON (When power indicator comes on), the device memorizes vehicle’s speed when switch is off and controls the fixed speed. 2. SET SPEED CONTROL This device compares the vehicle’s running speed and the memorized speed, and controls the driving power of the motor and the engine by calculating the cruise control requirements so that both speed become equivalent. 3. COAST CONTROL If the SET/COAST switch is continued to be ON during the running with the cruise control, the device recognizes the cruise control requirement is at 0 and decelerates the vehicle’s speed. Then the device memorizes the speed when the switch is off in order to control the fixed speed. In each time you operate SET/COAST switch momentarily (For about 0.5 second), the memorized speed is decreased in about 1.5 km/h. However, in case of the tap–down operation with more than 5–km/h gap between the memorized speed and vehicle’s running speed, the device memorizes the vehicle’s speed when the switch is off and controls the fixed speed. 4. ACCEL CONTROL If the RESUME/ACCEL switch is continued to be ON during the running with the cruise control, the device recognizes the cruise control is on the acceleration side and accelerates the vehicle’s speed. Then the running speed when the switch is off is memorized to control the fixed speed. In each time you operate RESUME/ACCEL switch momentarily (For about 0.5 second), the memorized speed is increased in about 1.5 km/h. However, if there is more than 5–km/h gap between the memorized speed and vehicle’s running speed, this operation does not change the memorized speed. (Tap–up operation is not available.) 5. RESUME CONTROL If the running speed is faster than the low speed limit after the cruise control is canceled manually, the fixed speed is controlled by the OFF–ON operation of RESUME/ACCEL switch, so that the vehicle’s speed returns to the memorized speed at the time the cruise control is released. 2001 PRIUS (EWD414U) 6. MANUAL CANCEL CONTROL When each of the following signals is input during driving with cruise control, the cruise control is released with turning the cruise control requirement to 0. (The memorized speed is maintained when following signals except the signal, main switch OFF is input.) ∗ Stop light switch ON (Pressing the brake pedal) ∗ Control switch’s cancel switch ON ∗ Main switch OFF 7. AUTO CANCEL FUNCTION A) The memorized speed is erased and the control is canceled if the following conditions occur. The power indicator blinks at that time until the main switch is turned ON. The speed control is unavailable unless the main switch is turned ON again. ∗ When the stop light switch breaks or short–circuits. ∗ When sudden change of the running speed signal occur. B) The memorized speed is erased and the control is canceled if the following conditions occur. ∗ When the malfunction of the stop light switch input circuit occurs. ∗ When the running speed becomes slower than 40km/h. ∗ When the running speed becomes slower than the speed that 16 km/h subtracted from the memorized speed. 8. REGENERATIVE SYSTEM OPERATION This system operates the motor as a generator to change the kinetic energy of the vehicle into the electricity when accel pedal release or foot braking controls the vehicle, and store the electricity in the battery. SERVICE HINTS C14 CRUISE CONTROL SW [COMB. SW] 5–4 : Approx. 1540 Ω with CANCEL SW on Approx. 240 Ω with RES/ACC SW on Approx. 630 Ω with SET/COAST SW on : PARTS LOCATION Code See Page A7 36 A13 A18 Code See Page Code See Page H10 C 37 J18 36 H11 A 37 J19 36 H12 B 37 B8 36 H13 E 37 J22 A 37 B11 36 H14 D 37 J23 B 37 B15 38 H16 A 38 J24 A 37 B16 38 H17 B 38 J25 B 37 A 38 I9 D 35 B18 B 38 I10 C 35 J27 J28 38 I11 A 35 C3 34 I12 B 35 C4 A 34 I13 E 35 C5 B 34 I14 F 35 C10 A 36 I15 C11 B 36 36 C14 D2 B 37 37 J26 37 A 37 B 37 J32 38 A 38 J33 B 38 37 M2 A 35 I17 38 M3 B 35 J1 37 M4 C 35 36 J2 A 37 P1 E9 C 36 J3 B 37 S3 E10 D 36 F10 37 J21 B17 B19 A J7 37 37 37 S8 A 39 34 J8 A 37 S9 B 39 J9 B 37 S10 C 39 F12 C 34 F13 D 34 J11 37 S11 D 39 F17 38 J16 37 S12 E 39 F18 38 J17 37 T4 37 G1 37 J18 37 W3 35 2001 PRIUS (EWD414U) TOYOTA HYBRID SYSTEM : RELAY BLOCKS Code 2 See Page 23 Relay Blocks (Relay Block Location) Engine Room R/B No.2 (Right Side of Reserve Tank) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1A See Page Junction Block and Wire Harness (Connector Location) 27 Engine Wire and Engine Room J/B (Engine Compartment Left) 27 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Panel LH) 2G 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) 2K 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) 1B 1F 1J 1K 2A 2B 2C 2D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IA1 IA2 See Page Joining Wire Harness and Wire Harness (Connector Location) 42 Engine Room Main Wire and Cowl Wire (Cowl Side Panel LH) IB1 42 Floor Wire and Cowl Wire (Cowl Side Panel LH) ID1 42 Instrument Panel Wire and Cowl Wire (Left Kick Panel) IE1 42 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) 42 Instrument Panel Wire and Floor Wire (Left Kick Panel) IH1 42 Floor Wire and Engine Room Main Wire (Left Kick Panel) IK1 44 Engine Wire and Engine Room Main Wire (Right Kick Panel) IF1 IF2 : GROUND POINTS Code EC See Page Ground Points Location 40 Engine Compartment Left 42 Cowl Side Panel LH IG 42 Cowl Side Panel RH IH 42 Right Kick Panel BI 46 Left Side of Rear Pillar BJ 46 Right Side of Rear Pillar ID IE : SPLICE POINTS Code See Page Wire Harness with Splice Points Code See Page Wire Harness with Splice Points E5 40 Engine Room Main Wire I8 44 Engine Wire I2 44 Instrument Panel Wire I9 44 Engine Room Main Wire I4 44 Cowl Wire B2 46 Floor Wire 2001 PRIUS (EWD414U) MEMO 2001 PRIUS (EWD414U) ENGINE CONTROL B B–W B–W B–W 7 AM2 IG2 6 B–W W–B ST2 B–W W–R FROM POWER SOURCE SYSTEM (SEE PAGE 50) I15 IGNITION SW 15A EFI 1 2G 11 2G B–W 2 B–W 5 2B W–R 2 2C 5 EFI RELAY 5 1 3 2 12 1F 1 1F 10 1A 13 1F 3 1A B B 1 2 3 1K B 2 1B CIR OPN RELAY 3 4 1A R–W G–R 4 IA2 14 IA1 G–R W–B FUSIBLE LINK BLOCK NO. 1 F12 C , F13 D 3 IG2 RELAY 15A AM2 1 C 1 G–R 5 2 1A B–R 3 1J G–R 9 1J IE BL J5 B B IA1 W–B W–B B B A A IG 2001 PRIUS (EWD414U) B J17 JUNCTION CONNECTOR W–B A 8 BC1 B A B 7 19 B A M J4 A , F16 FUEL PUMP A C A 3 JUNCTION CONNECTOR C A W–B J1 JUNCTION CONNECTOR BATTERY B W–B A J18 JUNCTION CONNECTOR A W–B F18 FUSIBLE LINK BLOCK NO. 2 120A MAIN 1 J7 JUNCTION CONNECTOR B–R B–G 1 D EA B I7 4 B B B–R 29 A EVP1 1 G–R 2 I7 B I7 I7 12 A IGT2 22 B THA 4 B–R I7 10 B VG 19 B 3 1 B B * 1 : SHIELDED 2001 PRIUS (EWD414U) B–R 13 A IGT3 Y 4 4 3 2 EVG 14 B THW G–R 2 2 BR I7 B–W E4 14 A 1 1 IGT4 I5 INJECTOR NO. 1 B–W W–B 1 I4 IGNITION COIL AND IGNITER NO. 4 B–W I3 IGNITION COIL AND IGNITER NO. 3 W–B 1 B–R 2 B–R B–W E3 Y 3 G W–B I2 IGNITION COIL AND IGNITER NO. 2 B–W W–B E4 O1 OIL PRESSURE SW +B 2 B–W Y–B IGF 4 E4 E1 ENGINE COOLANT TEMP. SENSOR 25 A 1 W IGT1 3 B–R 2 (* 1) I7 E3 R 3 I1 IGNITION COIL AND IGNITER NO. 1 W–B 4 B–W BR BR MREL 1 W–B G 11 A E3 W B–R W–B E4 (* 1) FC B–W W–B R–B 9 D B–W B B–R Y–G E4 M1 MASS AIR FLOW METER 25 C R–L IGSW V2 VSV (EVAP) 9 B B BATT JUNCTION CONNECTOR B–W B–W B B 3 B J24 A , J25 B B B G–R B–W C A G–R R–W B B B–W B–W W–B 2 5 B # 10 ENGINE CONTROL MODULE E 7 A , E 8 B , E 9 C , E10 D 12 B MOPS 5 1 BR B B (*1) ENGINE CONTROL B B B–W B B 1 BC1 R–W L–W B–R B–R 1 B 2 1 2 A # 30 #40 L 1 A # 20 1 2 7 A 8 A 6 BC1 B–R 2 BC1 6 B T2 THROTTLE CONTROL MOTOR (*1) 2 L 2 5 BC1 V6 VSV (PARGE FLOW SWITCHING VALVE) 2 I8 INJECTOR NO. 4 2 1 I7 INJECTOR NO. 3 1 I6 INJECTOR NO. 2 1 N1 NOISE FILTER (IGNITION) 1 B B–W B–W B–W C A L A B P A B V5 VSV (CANISTER CLOSED VALVE) E4 J5 B B–W E4 J4 A , B–W E4 JUNCTION CONNECTOR B–W B 11 C 13 C TBP CCV M– M+ 30 A GE01 E 7 A , E 8 B , E 9 C , E10 D ENGINE CONTROL MODULE HCLS VC PTNK VTA 22 C 2 B 23 B VTA2 21 B BR I7 2 1 PTNK E2 V4 VAPOR PRESSURE SENSOR BR BR I7 L P 1 2 3 VC VTA1 VTA2 E2 4 BR BR 3 VCC (* 1) L–R 4 BC1 L–R Y–R J9 B J8 A , C A 7 BC1 BR Y–R B B C A 3 BC1 JUNCTION CONNECTOR 3 BR 1 C A Y–R 2 BR 15 IO1 Y–R V1 VACUUM SENSOR (HC ADSORBER AND CATALYST SYSTEM) V–W 9 IO1 T3 THROTTLE POSITION SENSOR Y–R Y–R Y–R V–W 14 C BR I7 BR B B B B (*1) (*1) (*1) 2001 PRIUS (EWD414U) FROM POWER SOURCE SYSTEM (SEE PAGE 50) G–W J14 A , J15 B E A G–W D B 15A STOP 9 2K R–B 1 D STP ESTP 8 D R–Y ETH1 27 D L P BR ETH+ 28 D Y O HTE+ 19 D 1 G–W W–G G 23 A 24 A 21 C OCV+ 29 D (*1) (* 1) (* 1) Y–R 5 D SPD HTE– 6 D IA2 4 A FAN SPDO G 9 V–W 1 C2 CAMSHAFT TIMING OIL CONTROL VALVE TO COMBINATION METER 2 GO 10 B LG FROM FAN NO. 1 AND FAN NO. 2 RELAY W–G 2 S3 STOP LIGHT SW H12 B , H14 D HYBRID VEHICLE CONTROL ECU JUNCTION CONNECTOR * 1 : SHIELDED OCV– (* 1) 10 C GO 18 C SPHV HTE– 19 C 28 C HTE+ ETH+ 27 C 16 C ESTP ETH– E 7 A , E 8 B , E 9 C , E10 D ENGINE CONTROL MODULE I7 B Y G–Y (* 1) BR 4 3 1 BR (*1) H9 HEATED OXYGEN SENSOR (BANK 1 SENSOR 2) 2 B 2 J22 A , J23 B 4 D A E B JUNCTION CONNECTOR 3 E B (* 1) 1 I6 I6 1 IK1 H3 HEATED OXYGEN SENSOR (BANK 1 SENSOR 1) BR IK1 W BR I7 6 P–L 7 IK1 1 B 22 IE1 HT1B 7 D BR E B 2 BR IE1 W V3 VSV (HC ADSORBER AND CATALYST SYSTEM) B B–W P–L 6 IO1 2 OX1B 11 D BR 1 IE1 E11 16 D BR W OX1A 12 D P–L HT1A 1 D B–W HCC 20 C BR E2 18 B 12 IE1 B B (* 1) (* 1) (* 1) (* 1) 2001 PRIUS (EWD414U) ENGINE CONTROL FROM POWER SOURCE SYSTEM (SEE PAGE 50) 15A THRO P–B 8 1A C E G–R GR–L E P–B W–L GR C G–R 5 P–G ACT 4 GR–L J16 JUNCTION CONNECTOR LG NE W–L A8 A/C AMPLIFIER P–B GR W–L (* 1) GR (* 1) (* 1) (* 1) 6 A 3 D +BM NEO 22 D 6 C ACT 8 C TC 6 D SIL 14 D W 13 D MPX1 MPX2 E 7 A , E 8 B , E 9 C , E10 D ENGINE CONTROL MODULE E03 ME01 W–B 9 A W–B 3 A W–B BR R G (* 1) E02 31 A R B (* 1) I7 E01 21 A W–B E1 17 B (* 1) W–B NE+ 16 B W–B NE– 24 B W–B G2 10 A W–B KNK1 28 A I7 1 (* 1) (* 1) I7 I7 BR BR BR BR A A A A A A A A A B A B A B (* 1) (* 1) 2 G G C6 CRANKSHAFT POSITION SENSOR JUNCTION CONNECTOR J9 B 2 J8 A , 1 (* 1) 1 C1 CAMSHAFT POSITION SENSOR G K1 KNOCK SENSOR B G 1 EA1 BR (* 1) (* 1) EB 2001 PRIUS (EWD414U) EA FROM POWER SOURCE SYSTEM (SEE PAGE 50) * 1 : SHIELDED 10A GAUGE 7. 5A OBDII P–B 9 2D 5 2A 1 ID1 2 ID1 L W–L W–L G–R J26 JUNCTION CONNECTOR W–L G–R 11 7 13 16 4 B MPD2 SIL TC A A 14 ID2 MPX+ 8 2D BR 3 B 2 B 2 B L MP2+ W–B JUNCTION CONNECTOR 11 GR A7 A/C AMPLIFIER MALFUNCTION INDICATOR LAMP GR–B A A J24 A 4 SG 5 GR B CG 4 W–B D2 DATA LINK CONNECTOR 3 W–B 22 A MPD1 4 J18 B JUNCTION CONNECTOR COMBINATION METER BAT BR G1 GATEWAY ECU C10 A , C11 B GR–B 8 2K W–B 7 2A A IG J17 JUNCTION CONNECTOR J11 JUNCTION CONNECTOR 14 IO1 A ID 2001 PRIUS (EWD414U) BR W–B W–B BR 6 2B BR B (*1) (*1) GR–B 15 D P–B MPX+ (* 1) E W (* 1) A A D GR–L MPX– B8 BODY ECU 16 E J26 JUNCTION CONNECTOR P–B J22 A A A JUNCTION CONNECTOR W GR W–L GR–L EB IH ENGINE CONTROL SYSTEM OUTLINE This system utilizes an engine control module and maintains overall control of the engine, transmission and so on. An outline of the engine control is explained here. 1. INPUT SIGNALS (1) Engine coolant temp. signal circuit The engine coolant temp. sensor detects the engine coolant temp. and has a built–in thermistor with a resistance which varies according to the engine coolant temp. thus the engine coolant temp. is input in the form of a control signal into TERMINAL THW of the engine control module. (2) Intake air temp. signal circuit The intake air temp. sensor is installed in the mass air flow meter and detects the intake air temp., which is input as a control signal into TERMINAL THA of the engine control module. (3) Oxygen sensor signal circuit The oxygen density in the exhaust gases is detected and input as a control signal into TERMINALS OX1A and OX1B of the engine control module. (4) RPM signal circuit Camshaft position and crankshaft position are detected by the camshaft position sensor and crankshaft position sensor. Camshaft position is input as a control signal to TERMINAL G2 of the engine control module, and engine RPM is input into TERMINAL NE+. (5) Throttle signal circuit The throttle position sensor detects the throttle valve opening angle, which is input as a control signal into TERMINALS VTA and VTA2 of the engine control module. (6) Vehicle speed signal circuit The vehicle speed signal from brake ECU, detects the vehicle speed and inputs a control signal into TERMINAL SPD of the engine control module via the combination meter. (7) Battery signal circuit Voltage is constantly applied to TERMINAL BATT of the engine control module. When the ignition SW is turned on, the voltage for engine control module start–up power supply is applied to TERMINAL +B of the engine control module via EFI relay. (8) Engine knock signal circuit Engine knocking is detected by knock sensor and the signal is input into TERMINAL KNK1 of the engine control module as a control signal. 2. CONTROL SYSTEM ∗ SFI system The SFI system monitors the engine condition through the signals, which are input from each sensor to the engine control module. The best fuel injection volume is decided based on this data and the program memorized by the engine control module, and the control signal is output to TERMINALS #10, #20, #30 and #40 of the engine control module to operate the injector. (Inject the fuel). The SFI system produces control of fuel injection operation by the engine control module in response to the driving conditions. ∗ ESA system The ESA system monitors the engine condition through the signals, which are input to the engine control module from each sensor. The best ignition timing is detected according to this data and the memorized data in the engine control module, and the control signal is output to TERMINALS IGT1, IGT2, IGT3 and IGT4. This signal controls the ignition coil and igniter to provide the best ignition timing for the driving conditions. ∗ Fuel pump control system The engine control module operation outputs to TERMINAL FC and controls the CIR OPN relay. Thus controls the fuel pump drive speed in response to conditions. 3. DIAGNOSIS SYSTEM With the diagnosis system, when there is a malfunctioning in the engine control module signal system, the malfunction system is recorded in the memory. The malfunctioning system can then be found by reading the display (Code) of the malfunction indicator lamp. 4. FAIL–SAFE SYSTEM When a malfunction occurs in any system, if there is a possibility of engine trouble being caused by continued control based on the signals from that system, the fail–safe system either controls the system by using data (Standard values) recorded in the engine control module memory or else stops the engine. 2001 PRIUS (EWD414U) SERVICE HINTS E7 (A), E8 (B), E9 (C), E10 (D) ENGINE CONTROL MODULE BATT–E1 : Always approx. 9–14 volts +B–E1 : 9–14 volts with the ignition SW on and the engine stopping VC–E2 : 4.5–5.5 volts with the ignition SW on and the engine stopping IGF–E1 : Pulse generation with the engine idling THA–E2 : 0.5–3.4 volts with the engine idling and the intake air temp. 20°C (68°F) THW–E2 : 0.2–1.0 volts with the engine idling and the engine coolant temp. 80°C (176°F) W–E1 : 9–14 volts with the engine idling : 0–3 volts with the ignition SW on and the engine coolant temp. sensor connector disconnects ESTP–E1 : 9–14 volts with the brake pedal depressed FC–E01 : 9–14 volts with the ignition SW on and the engine stopping : 0–3 volts with the engine idling +BM–E1 : Always approx. 9–14 volts MREL–E1 : 9–14 volts with the ignition SW on and the engine stopping EVP1–E1 : 9–14 volts with the ignition SW on and the engine stopping HT1A, HT1B : 9–14 volts with the ignition SW on and the engine stopping TC–E1 : 9–14 volts with the ignition SW on and the engine stopping KNK1–E2 : Pulse generation with the engine idling NE+, G2–NE– : Pulse generation with the engine idling OCV+ –OCV– : Pulse generation with the ignition SW on and the engine stopping IGT1, IGT2, IGT3, IGT4–E1 : Pulse generation with the engine idling #10, #20, #30, #40–E01 : Pulse generation with the engine idling E01, E02, E03, E1, E2, ME01–GROUND : Always continuity E1 ENGINE COOLANT TEMP. SENSOR 2–1 : Approx. 14.96 kΩ (–20 °C, –4 °F) Approx. 2.44 kΩ (20 °C, 68 °F) Approx. 0.31 kΩ (80 °C, 176 °F) Approx. 0.14 kΩ (110 °C, 230 °F) : PARTS LOCATION Code See Page Code See Page B 37 D 37 Code See Page A7 36 H12 J17 37 A8 36 H14 B8 36 I1 35 J22 A 37 C1 34 I2 35 J23 B 37 C2 34 I3 35 J24 A 37 C6 34 I4 35 J25 B 37 J18 37 C10 A 36 I5 35 J26 37 C11 B 36 I6 35 K1 35 D2 36 I7 35 M1 35 E1 34 I8 35 N1 35 E7 A 36 I15 37 O1 35 E8 B 36 J1 37 S3 37 E9 C 36 J4 A 37 T2 35 E10 D 36 J5 B 37 T3 35 F12 C 34 37 V1 35 F13 D 34 J8 A 37 V2 35 F16 38 J9 B 37 V3 35 F18 38 37 V4 39 G1 37 J14 A 37 V5 39 H3 34 J15 B 37 V6 39 H9 37 J7 J11 J16 37 2001 PRIUS (EWD414U) ENGINE CONTROL ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1A See Page Junction Block and Wire Harness (Connector Location) 27 Engine Wire and Engine Room J/B (Engine Compartment Left) 27 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Panel LH) 2G 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) 2K 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) 1B 1F 1J 1K 2A 2B 2C 2D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code EA1 See Page Joining Wire Harness and Wire Harness (Connector Location) 40 Engine Wire and Engine No.4 Wire (Near the Radiator Fan) 42 Engine Room Main Wire and Cowl Wire (Cowl Side Panel LH) 42 Instrument Panel Wire and Cowl Wire (Left Kick Panel) IE1 42 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IK1 44 Engine Wire and Engine Room Main Wire (Right Kick Panel) IO1 44 Engine Wire and Cowl Wire (Right Kick Panel) BC1 46 Cowl Wire and Fuel Tank Wire (Near the Fuel Tank) IA1 IA2 ID1 ID2 : GROUND POINTS Code EA See Page Ground Points Location 40 Engine Block 42 Cowl Side Panel LH IG 42 Cowl Side Panel RH IH 42 Right Kick Panel BL 46 Near the Fuel Tank EB ID IE : SPLICE POINTS Code E3 E4 See Page 40 Wire Harness with Splice Points Engine Wire Code See Page Wire Harness with Splice Points I6 44 Instrument Panel Wire I7 44 Engine Wire 2001 PRIUS (EWD414U) MEMO 2001 PRIUS (EWD414U) HYBRID VEHICLE IMMOBILISER SYSTEM FROM POWER SOURCE SYSTEM (SEE PAGE 50) 7 AM2 7. 5A ECU–B IG2 6 B–W W–R ST2 5 2C F A C A 1 2G D2 DATA LINK CONNECTOR 3 H14 HYBRID VEHICLE CONTROL ECU OP1 R–G W–R B–W H B J27 A , J28 B J24 A JUNCTION CONNECTOR JUNCTION CONNECTOR C A 2 2C R–G I15 IGNITION SW FCVC 11 7 B–R 8 ID1 11 ID2 A B–W 10 ID2 J20 JUNCTION CONNECTOR 15A AM2 B–W R–G 9 1J R–G B–R A 2 1B 2 3 1 +B 8 D HEVC W–B J24 A , J25 B A B JUNCTION CONNECTOR W–B A A W–B W–B W–B J27 A , J28 B U1 UNLOCK WARNING SW L–B 2 JUNCTION CONNECTOR L–B B A D6 DOOR COURTESY SW FRONT LH BR 8 2D IB1 1 A 8 2K L–B J12 A , J13 B JUNCTION CONNECTOR R–W 3 J10 JUNCTION CONNECTOR 9 ID1 D B R–W A A JUNCTION CONNECTOR R3 B , R4 C E B LG–B 7 B RADIO AND PLAYER 8 C W–B L–B R–W LG–B D A 12 W–B J20 JUNCTION CONNECTOR B BR F18 FUSIBLE LINK BLOCK NO. 2 F B GND T4 TRANSPONDER KEY COMPUTER A B C7 CENTER CLUSTER SW 4 BATTERY 7 8 ID2 B–G 120A MAIN KSW LG–B 6 1 CTY 6 J27 A , J28 B 1 D IND 5 LG–B F12 C , F13 D 1 C FUSIBLE LINK BLOCK NO. 1 B IG A A 1 IF ID 2001 PRIUS (EWD414U) J11 JUNCTION CONNECTOR SERVICE HINTS T4 TRANSPONDER KEY COMPUTER 1–GROUND : Always approx. 12 volts 12–GROUND : Always continuity U1 UNLOCK WARNING SW 1–2 : Closed with the ignition key in cylinder : PARTS LOCATION Code See Page Code See Page Code See Page C7 36 I15 37 J25 B 37 D2 36 J10 37 J27 A 37 D6 38 J11 37 J28 B 37 A 37 R3 B 37 B 37 R4 C 37 F12 F13 C 34 J12 D 34 J13 F18 38 H14 37 J20 J24 A 37 T4 37 37 U1 37 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1B See Page Junction Block and Wire Harness (Connector Location) 27 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Panel LH) 2G 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) 2K 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) 1J 2C 2D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IB1 ID1 ID2 See Page Joining Wire Harness and Wire Harness (Connector Location) 42 Floor Wire and Cowl Wire (Cowl Side Panel LH) 42 Instrument Panel Wire and Cowl Wire (Left Kick Panel) : GROUND POINTS Code See Page Ground Points Location ID 42 Cowl Side Panel LH IF 42 Left Kick Panel 2001 PRIUS (EWD414U) HEADLIGHT (w/ DAYTIME RUNNING LIGHT) FROM POWER SOURCE SYSTEM (SEE PAGE 50) 1 1 5 1 3 DRL RELAY 7. 5A DRL 30A HEAD 2 2 2 3 1 3 3 3 3 4 HEAD RELAY R–L R–W W–B R–G 2 3 4 DIM RELAY 1 3 2 8 1F 17 IA2 L 9 IA1 R–B R–B R–B E2 3 3 H1 HEADLIGHT LH 1 2 1 W–B 2 R H2 HEADLIGHT RH R–W G–R L R–G R–W R–G R–Y 5 1E 6 IA2 G–R 2 1E R–G R–G 10A HEAD HI (RH) 7 1F R–Y 10A HEAD HI (LH) 6 1F R 10A HEAD LO (LH) 10A HEAD LO (RH) 3 1E A J1 JUNCTION CONNECTOR IE 2001 PRIUS (EWD414U) FROM POWER SOURCE SYSTEM (SEE PAGE 50) 7. 5A ECU–B 10A GAUGE H B R–G 16 IA2 8 ID1 JUNCTION CONNECTOR J27 A , J28 B R–G F A A R–W 7 1J L–Y R–G R–W 10 2K R–L 5 2C 15A DOME C J20 JUNCTION CONNECTOR R–G A C R–G R–L R–G 3 12 L E CHG– IND 9 2 5 7 2I 2 2G 10 2A 4 2A R–G E R–G J20 JUNCTION CONNECTOR LIGHT CONTROL SW LOW R–Y E A 7 TAIL HEAD 14 L FLASH Y–B 13 16 7 2A C13 COMBINATION SW W–B R RDY 9 A W–B H 17 B 21 HIGH R–W BODY ECU HRLY 17 1 B8 A , B9 B 2 B 7 ID2 P2 PARKING BRAKE SW R–W 3 ID2 DIMMER SW 8 OFF E B HIGH BEAM E Y–B E J12 A , J13 B E R–Y R–G JUNCTION CONNECTOR L–O R–G R–B C10 COMBINATION METER 11 L–Y PKB 8 L HI 7 HEAD H 1 IG 6 2B A J17 JUNCTION CONNECTOR 5 ID2 R IG 2001 PRIUS (EWD414U) J11 JUNCTION CONNECTOR ID BR DRL 2 +B R–G H–LP L DIM W–B D5 DIODE (DAYTIME RUNNING LIGHT) 6 Y–B 1 D3 DAYTIME RUNNING LIGHT RELAY 4 IH HEADLIGHT (w/ DAYTIME RUNNING LIGHT) SYSTEM OUTLINE When the ignition SW is turned on ST position and ”READY” signal from engine control module is sent to the daytime running light relay via body ECU. If the parking brake pedal is depressed (Parking brake SW is on) at that time, the daytime running light system does not operate. If the parking brake pedal is released (Parking brake SW is off), the daytime running light system operates and the low beam headlight comes on. SERVICE HINTS HEAD RELAY 1–2 : Closed with the light control SW at HEAD position or the dimmer SW at FLASH position Closed with the engine running and the parking brake lever is released (Parking brake SW off) D3 DAYTIME RUNNING LIGHT RELAY 12–GROUND : Approx. 12 volts with the ignition SW at ON position 3–GROUND : Always approx. 12 volts 11–GROUND : Continuity with the parking brake lever pulled up 2–GROUND : Always continuity 8–GROUND : Continuity with the dimmer SW at HIGH or FLASH position : PARTS LOCATION Code See Page Code See Page Code See Page B8 A 36 H1 34 J17 B9 B 36 H2 34 J20 C10 36 J1 37 J27 A 37 C13 36 J11 37 J28 B 37 D3 36 J12 A 37 D5 36 J13 B 37 P2 : RELAY BLOCKS Code 3 See Page 24 Relay Blocks (Relay Block Location) Engine Room R/B No.3 (Engine Compartment Right) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1E 1F 27 Engine g Room Main Wire and Engine g Room J/B (Engine ( g Compartment Left)) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl ( Side Panel LH)) 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) 1J 2A 2B 2C 2G 2I 2K : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IA1 IA2 ID1 ID2 See Page Joining Wire Harness and Wire Harness (Connector Location) 42 Engine Room Main Wire and Cowl Wire (Cowl Side Panel LH) 42 Instrument Panel Wire and Cowl Wire (Left Kick Panel) : GROUND POINTS Code ID See Page Ground Points Location 42 Cowl Side Panel LH IG 42 Cowl Side Panel RH IH 42 Right Kick Panel IE 2001 PRIUS (EWD414U) 37 37 37 : SPLICE POINTS Code E2 See Page 40 Wire Harness with Splice Points Code Engine Room Main Wire 2001 PRIUS (EWD414U) See Page Wire Harness with Splice Points HEADLIGHT (w/o DAYTIME RUNNING LIGHT) 4 1 1 SHORT PIN HEAD RELAY 2 1 1B 8 1F 4 6 1F R–G H2 HEADLIGHT RH J20 JUNCTION CONNECTOR 2 1 2 R–G 1 R–Y R–W JUNCTION CONNECTOR R–Y R–W J4 A , 3 ID2 1 C F A E B J5 B J5 B F A D B E A 7 IA1 3 IA1 E A J4 A , R–W E R–G R–Y E 2 B9 BODY ECU FUSIBLE LINK BLOCK NO. 1 F12 C , F13 D 3 H1 HEADLIGHT LH JUNCTION CONNECTOR B E 7 1F 3 IA2 R–W 6 10A HEAD (RH) R–L 3 10A HEAD (LH) R–W 1 SHORT PIN R–G 2 HRLY H 17 1 D L R–G R R–Y B–G R–G TAIL HEAD D B R–G R–G 17 JUNCTION CONNECTOR R–Y 7 J12 A , J13 B R–W 8 F A LOW 7 2I HIGH FLASH C13 COMBINATION SW 10 2A 16 L BATTERY 13 OFF W–B DIMMER SW LIGHT CONTROL SW 120A MAIN F18 FUSIBLE LINK BLOCK NO. 2 1 R 5 ID2 A J17 JUNCTION CONNECTOR IG 2001 PRIUS (EWD414U) F A FROM POWER SOURCE SYSTEM (SEE PAGE 50) 15A DOME L–Y 7 1J 2 2G 4 2A L L L HEAD HIGH BEAM C10 COMBINATION METER 21 17 L 14 7 2A BR 6 2B IH 2001 PRIUS (EWD414U) HEADLIGHT (w/o DAYTIME RUNNING LIGHT) SERVICE HINTS HEAD RELAY 1–2 : Closed with the light control SW at HEAD position or the dimmer SW at FLASH position C13 COMBINATION SW 13–16 : Continuity with the light control SW at HEAD position 8–16 : Continuity with the dimmer SW at FLASH position 7–16 : Continuity with the dimmer SW at HIGH or FLASH position : PARTS LOCATION Code See Page Code See Page Code See Page B9 36 F18 38 J12 C10 36 H1 34 J13 C13 36 H2 34 J17 37 J20 37 F12 C 34 J4 A 37 F13 D 34 J5 B 37 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1B 1F 27 Engine g Room Main Wire and Engine g Room J/B (Engine ( g Compartment Left)) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Panel LH) 2G 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) 2I 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) 1J 2A 2B : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IA1 IA2 ID2 See Page Joining Wire Harness and Wire Harness (Connector Location) 42 Engine Room Main Wire and Cowl Wire (Cowl Side Panel LH) 42 Instrument Panel Wire and Cowl Wire (Left Kick Panel) : GROUND POINTS Code See Page Ground Points Location IG 42 Cowl Side Panel RH IH 42 Right Kick Panel 2001 PRIUS (EWD414U) A 37 B 37 MEMO 2001 PRIUS (EWD414U) TAILLIGHT 1 5 7. 5A TAIL TAIL RELAY 6 2K 7 2J 5 2F G LG 1 2H 3 2 ID2 10 5 2L G G 2 IA1 J4 A , J5 B G W LG JUNCTION CONNECTOR D F A B 11 TRLY T D A B9 BODY ECU F B G G F6 FRONT SIDE MARKER LIGHT RH W–B 2 B–G 1 14 OFF 1 1 2 2 TAIL HEAD E1 W–B 16 W–B C13 LIGHT CONTROL SW [COMB. SW] A J7 JUNCTION CONNECTOR W–B A BATTERY W–B 120A MAIN F18 FUSIBLE LINK BLOCK NO. 2 F3 FRONT PARKING LIGHT LH W–B LG–R F5 FRONT SIDE MARKER LIGHT LH W–B 6 ID2 1 D 1 G 100A DC/DC F11 B , F13 D FUSIBLE LINK BLOCK NO. 1 1 B F4 FRONT PARKING LIGHT RH W–B LG–R G 18 A A J17 JUNCTION CONNECTOR IG J1 JUNCTION CONNECTOR IE 2001 PRIUS (EWD414U) E1 W–B E1 2 1 W–B W–B 1 2 G B A BI 1 6 5 C B C B 1 2 JUNCTION CONNECTOR J32 A , J33 B W–B BK 2001 PRIUS (EWD414U) G A A G R7 TAILLIGHT RH [REAR COMB. LIGHT RH] G A A L3 LICENSE PLATE LIGHT RH A A G A A G R6 TAILLIGHT LH [REAR COMB. LIGHT LH] G JUNCTION CONNECTOR W–B W–B W–B A A L2 LICENSE PLATE LIGHT LH G G J32 A , J33 B A B A A 1 6 5 TAILLIGHT SERVICE HINTS TAIL RELAY 5–3 : Closed with the light control SW at TAIL or HEAD position : PARTS LOCATION Code See Page Code 36 C13 36 F3 34 F4 34 J4 A F5 34 J5 B F6 34 34 F11 B F13 See Page B9 D Code 34 J32 F18 38 J33 J1 37 See Page A 38 B 38 L2 38 37 L3 38 37 R6 39 J7 37 R7 39 J17 37 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 2F 2H 2J 2K 2L See Page Junction Block and Wire Harness (Connector Location) 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) 31 Floor Wire and Instrument Panel J/B (Cowl Side Panel LH) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IA1 42 Engine Room Main Wire and Cowl Wire (Cowl Side Panel LH) ID2 42 Instrument Panel Wire and Cowl Wire (Left Kick Panel) : GROUND POINTS Code See Page Ground Points Location IE 42 Cowl Side Panel LH IG 42 Cowl Side Panel RH BI 46 Left Side of Rear Pillar BK 46 Back Panel Center : SPLICE POINTS Code E1 See Page 40 Wire Harness with Splice Points Code Engine Room Main Wire 2001 PRIUS (EWD414U) See Page Wire Harness with Splice Points MEMO 2001 PRIUS (EWD414U) B–G F11 B , F13 D 1 D LG–R 1 B 11 TRLY T B9 BODY ECU 2 18 1 6 ID2 A J17 JUNCTION CONNECTOR IG 2001 PRIUS (EWD414U) 2 1 BR 8 M7 MULTI DISPLAY LG 6 2K C9 CIGARETTE LIGHTER ILLUMINATION LG 1 2H LG LG LG 2 A22 ASHTRAY ILLUMINATION LG–R W TAIL RELAY W–L W–L 100A DC/DC FUSIBLE LINK BLOCK NO. 1 1 BR W–B 1 C13 LIGHT CONTROL SW [COMB. SW] 120A MAIN F18 FUSIBLE LINK BLOCK NO. 2 ILLUMINATION 5 5A PANEL 3 1 2D LG LG LG LG 2 ID2 6 OFF 14 TAIL HEAD 16 W–L W–L BATTERY IF TC B W–L E W–L D B E A 5 ILL– W–L E W–B 2001 PRIUS (EWD414U) 6 B C C ID 7 B 14 A LG–R W–B A A 8 2D 7 2A 8 2K 6 2B A J11 JUNCTION CONNECTOR IH COMBINATION METER C10 A , C11 B L1 LIGHT CONTROL RHEOSTAT L JUNCTION CONNECTOR L E W–L 3 W–B LG L–Y LG BR C 6 W–B J21 JUNCTION CONNECTOR C T W–B B C 4 J24 JUNCTION CONNECTOR A 10 J21 JUNCTION CONNECTOR A LG F B W–L LG H A W–B 5 A 5 C7 CENTER CLUSTER SW F B W–L LG H A J22 A , J23 B B W–L LG H A JUNCTION CONNECTOR W–B W–L A J21 JUNCTION CONNECTOR 10 B R2 A , R3 B F B RADIO AND PLAYER LG H A W–L W–L 2 W–L 5 H7 HAZARD WARNING SW LG LG W–L W–L J21 JUNCTION CONNECTOR W–L FROM POWER SOURCE SYSTEM (SEE PAGE 50) 15A DOME 7 1J LG LG 2 2G J27 A , J28 B 4 2A F B 21 A ILLUMINATION SERVICE HINTS TAIL RELAY 5–3 : Closed with the light control SW at TAIL or HEAD position C13 COMBINATION SW 14–16 : Closed with the light control SW at TAIL or HEAD position : PARTS LOCATION Code See Page Code D Code 34 See Page 36 B9 36 F18 38 J27 A 37 C7 36 H7 37 J28 B 37 C9 F13 See Page A22 J24 37 36 J11 37 L1 C10 A 36 J17 37 M7 C11 B 36 J21 37 R2 A 37 R3 B 37 C13 F11 B 36 J22 A 37 34 J23 B 37 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1J See Page Junction Block and Wire Harness (Connector Location) 27 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl ( Side Panel LH)) 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) 2A 2B 2D 2G 2H 2K : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code ID2 See Page 42 Joining Wire Harness and Wire Harness (Connector Location) Instrument Panel Wire and Cowl Wire (Left Kick Panel) : GROUND POINTS Code See Page Ground Points Location ID 42 Cowl Side Panel LH IF 42 Left Kick Panel IG 42 Cowl Side Panel RH IH 42 Right Kick Panel 2001 PRIUS (EWD414U) 37 37 MEMO 2001 PRIUS (EWD414U) TURN SIGNAL AND HAZARD WARNING LIGHT FROM POWER SOURCE SYSTEM (SEE PAGE 50) 10A GAUGE 6 1J H7 HAZARD SW [HAZARD WARNING SW] W–B 10A TURN–HAZ W–B 10 2K W R–L 3 C G–B G–B G–R 6 IA1 J20 JUNCTION CONNECTOR 4 C 8 3 C13 TURN SIGNAL SW [COMB. SW] RH 4 2K G–Y G–Y W–B 1 LH LR 3 2F 2 J12 A , J13 B 7 JUNCTION CONNECTOR 6 B E 5 L–B ER LL B A B A G–B T5 TURN SIGNAL FLASHER RELAY EL 3 HAZ 1 B B 2 W–B W–B G–Y 2 1 2 W–B IG F7 FRONT TURN SIGNAL LIGHT LH 1 B F8 FRONT TURN SIGNAL LIGHT RH G–Y R–L 4 12 2J G–R W 4 ID1 A J7 JUNCTION CONNECTOR A G–Y A A J4 JUNCTION CONNECTOR A A A W–B A W–B W–B J18 JUNCTION CONNECTOR 11 IA1 G–Y A A J17 JUNCTION CONNECTOR IG J1 JUNCTION CONNECTOR IE 2001 PRIUS (EWD414U) W–B C10 TURN SIGNAL INDICATOR LIGHT [COMB. METER] D B J22 A , J23 B W–B E A JUNCTION CONNECTOR LH RH A J24 JUNCTION CONNECTOR 19 18 14 W–B L L L A 8 2D 2 2A 1 2A 7 2A R7 REAR TURN SIGNAL LIGHT RH [REAR COMB. LIGHT RH] R6 REAR TURN SIGNAL LIGHT LH [REAR COMB. LIGHT LH] 3 5 BR 6 2B 3 5 W–B W–B 3 2M G–Y 5 2M G–B 8 2K C B W–B J32 A , J33 B JUNCTION CONNECTOR BR W–B B A A J11 JUNCTION CONNECTOR ID BI BK 2001 PRIUS (EWD414U) IH TURN SIGNAL AND HAZARD WARNING LIGHT SERVICE HINTS T5 TURN SIGNAL FLASHER RELAY 1–GROUND : Approx. 12 volts with the ignition SW at ON position 4–GROUND : Always approx. 12 volts 2, 3–GROUND : Changes from approx. 12 to 0 volts with the ignition SW at ON position and the turn signal SW at LEFT or RIGHT position or the hazard SW at ON position 5–GROUND : Continuity with the ignition SW at ON position and the turn signal SW at LEFT position 6–GROUND : Continuity with the ignition SW at ON position and the turn signal SW at RIGHT position 8–GROUND : Continuity with the hazard SW at ON position 7–GROUND : Always continuity : PARTS LOCATION Code See Page Code See Page J11 Code 37 See Page C10 36 J24 37 C13 36 J12 A 37 J32 A 38 F7 34 J13 B 37 J33 B 38 F8 34 J17 37 R6 39 H7 37 J18 37 R7 39 J1 37 J20 37 T5 37 J4 37 J22 A 37 J7 37 J23 B 37 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1J See Page Junction Block and Wire Harness (Connector Location) 27 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl ( Side Panel LH)) 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) 31 Floor Wire and Instrument Panel J/B (Cowl Side Panel LH) 2A 2B 2D 2F 2J 2K 2M : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IA1 42 Engine Room Main Wire and Cowl Wire (Cowl Side Panel LH) ID1 42 Instrument Panel Wire and Cowl Wire (Left Kick Panel) : GROUND POINTS Code ID See Page Ground Points Location 42 Cowl Side Panel LH IG 42 Cowl Side Panel RH IH 42 Right Kick Panel BI 46 Left Side of Rear Pillar BK 46 Back Panel Center IE 2001 PRIUS (EWD414U) MEMO 2001 PRIUS (EWD414U) STOP LIGHT FROM POWER SOURCE SYSTEM (SEE PAGE 50) 15A STOP R–B 9 2K 2 S3 STOP LIGHT SW G–W 1 E J14 JUNCTION CONNECTOR G–W E IB1 G–W 9 C A C A J30 A , J31 B JUNCTION CONNECTOR G–W R7 STOP LIGHT RH [REAR COMB. LIGHT RH] 2 1 2 W–B 5 B A 5 C B W–B C B 2 J32 A , J33 B JUNCTION CONNECTOR W–B R6 STOP LIGHT LH [REAR COMB. LIGHT LH] H15 HIGH MOUNTED STOP LIGHT W–B G–W A B G–W A B W–B BI BK 2001 PRIUS (EWD414U) SERVICE HINTS S3 STOP LIGHT SW 2–1 : Closed with the brake pedal depressed : PARTS LOCATION Code See Page H15 J14 J30 A Code See Page 2K B 38 R6 39 37 J32 A 38 R7 39 38 J33 B 38 S3 37 See Page 31 Junction Block and Wire Harness (Connector Location) Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IB1 See Page 42 Joining Wire Harness and Wire Harness (Connector Location) Floor Wire and Cowl Wire (Cowl Side Panel LH) : GROUND POINTS Code See Page J31 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code Code 38 See Page Ground Points Location BI 46 Left Side of Rear Pillar BK 46 Back Panel Center 2001 PRIUS (EWD414U) IH MPX2 14 D MPX1 ENGINE CONTROL MODULE 19 C HTE+ MP2+ RL HTE– B B 18 C HTE– A E 9 C , E10 D IG 2001 PRIUS (EWD414U) A A 8 2D 8 2K J17 JUNCTION CONNECTOR ID JUNCTION CONNECTOR 14 E MPX+ JUNCTION CONNECTOR R–B C10 A , C11 B B A 4 5 A J11 JUNCTION CONNECTOR BI R–B R–B L 1 B IF1 N2 NAVIGATION ECU R–B R–B R–B R–B JUNCTION CONNECTOR J27 A , J28 B R–L D A R7 BACK–UP LIGHT RH [REAR COMB. LIGHT RH] W–B W–B J30 A , J31 B E R6 BACK–UP LIGHT LH [REAR COMB. LIGHT LH] 29 D W–B 4 J22 JUNCTION CONNECTOR 1 J32 A , J33 B 4 J24 JUNCTION CONNECTOR 9 W–B MPD2 W–B MPD1 19 D W–B 11 HTE+ W–B W–G R–L 3 2C W–B 13 D 4 J18 JUNCTION CONNECTOR MPX– R–B COMBINATION METER W–B 16 BR MPX+ 3 B P1 PARK/NEUTRAL POSITION SW 11 Y 15 H13 E , H14 D 2 B HYBRID VEHICLE CONTROL ECU GR R–B 1 (SHIELDED) 7 2A GR–B 2 A7 A/C AMPLIFIER 5 G1 GATEWAY ECU GR–B 14 A GR 6 2B B8 BODY ECU L 3 GR–L BR BACK–UP LIGHT FROM POWER SOURCE SYSTEM (SEE PAGE 50) R–B 10A GAUGE D A B B B5 BACK–UP LIGHT RELAY 5 IJ1 14 REV B A B B E 4 5 C B B A BK SERVICE HINTS P1 PARK/NEUTRAL POSITION SW 4–1 : Closed with the shift lever at R position B5 BACK–UP LIGHT RELAY 3–5 : Closed with the shift lever at R position : PARTS LOCATION Code See Page A7 36 B5 36 B8 36 Code H14 See Page D Code See Page 37 J31 B 38 J11 37 J32 A 38 J17 37 J33 B 38 C10 A 36 J18 37 N2 39 C11 B 36 J22 37 P1 37 E9 C 36 J24 37 R6 39 E10 D 36 J27 A 37 R7 39 37 J28 B 37 37 J30 A 38 G1 H13 E ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 2A 2B 2C 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Panel LH) 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) 2D 2K : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IF1 42 Instrument Panel Wire and Floor Wire (Left Kick Panel) IJ1 44 Floor No.3 Wire and Instrument Panel Wire (Under the Instrument Panel Center) : GROUND POINTS Code See Page Ground Points Location ID 42 Cowl Side Panel LH IG 42 Cowl Side Panel RH IH 42 Right Kick Panel BI 46 Left Side of Rear Pillar BK 46 Back Panel Center 2001 PRIUS (EWD414U) LIGHT AUTO TURN OFF FROM POWER SOURCE SYSTEM (SEE PAGE 50) W (*1) 10A GAUGE 1 4 1 3 1 1B 1 2 3 5 2C 6 2K (* 1) R–G 7. 5A TAIL 2 8 1F 7. 5A ECU–B 5 TAIL RELAY SHORT PIN (* 1) (*2) HEAD RELAY 2 30A HEAD 1 1 2H (*2) 2 R–W (*2) * 1 : W/ DAYTIME RUNNING LIGHT * 2 : W/O DAYTIME RUNNING LIGHT (* 1) D3 DAYTIME RUNNING J20 LIGHT RELAY JUNCTION CONNECTOR R–G R–G R–G LG R–G 6 IA2 6 (* 2) R–W B W H–LP H 7 B F B 9 2C (*1) 9 B B 12 KSW BODY ECU DCTY 5 ID2 6 ID2 LG–R 13 14 D A OFF C13 LIGHT CONTROL SW [COMB. SW] 3 8 2D IB1 R–W HEAD W–B 16 A A 8 2K W–B TAIL A B R–W R F B 1 W–B 1 2K 1 B J12 A , J13 B 3 E JUNCTION CONNECTOR 18 B R–W 17 B LG–R F18 FUSIBLE LINK BLOCK NO. 2 T R B–G H 1 A A J17 JUNCTION CONNECTOR IG D6 DOOR COURTESY SW FRONT LH J11 JUNCTION CONNECTOR ID 2001 PRIUS (EWD414U) J24 A , J25 B IG JUNCTION CONNECTOR TAIL W–B TRLY B9 B 1 BATTERY 15 17 11 B HRLY 2 W–B 2 B U1 UNLOCK WARNING SW LG R–W 3 ID2 1 D 120A MAIN L–B R–W (*2) FUSIBLE LINK BLOCK NO. 1 1 C 100A DC/DC 1 B F11 B , F12 C , F13 D E L–B F R–G J27 JUNCTION CONNECTOR L–B (*1) 2 ID2 E SYSTEM OUTLINE With the ignition SW turned on, the current flows to TERMINAL 15 of the body ECU through GAUGE fuse. Voltage is applied at all times to TERMINAL (A) 11 of the body ECU through the TAIL relay. Coil side, and to TERMINAL (A) 2 through the HEAD relay coil side (w/o daytime running light) or through the daytime running light relay (w/ daytime running light). 1. NORMAL LIGHTING OPERATION With the light control SW turned to TAIL position, a signal is input into TERMINAL (A) 18 of the body ECU. Due to this signal, the current flowing to TERMINAL (A) 11 of the body ECU flows to TERMINAL (A) 18 to TERMINAL 14 of the light control SW to TERMINAL 16 to GROUND, and taillight relay causes taillights to turn on. With the light control SW turned to HEAD position, a signal is input into TERMINALS (A) 17 and (A) 18 of the body ECU. Due to this signal, the current flowing to TERMINAL (A) 2 of the body ECU flows to TERMINAL (A) 17 to TERMINAL 13 of the light control SW to TERMINAL 16 to GROUND in the headlight circuit, and causes taillight and HEAD relay to turn the lights on. The taillight circuit is same as above. 2. LIGHT AUTO TURN OFF OPERATION With light on and ignition SW turned off (Input signal goes to TERMINAL 15 of the body ECU), when the driver’s door is opened (Input signal goes to TERMINAL 3 of the body ECU), the ECU operates and the current is cut off which flows from TERMINAL (A) 11 of the body ECU to TERMINAL (A) 18 in taillight circuit and from TERMINAL (A) 2 to TERMINAL (A) 17 in headlight circuit. As a result, all lights are turned off automatically. SERVICE HINTS HEAD RELAY 2–1 : Closed with the light control SW at HEAD position or the dimmer SW at FLASH position Closed with the engine running and the parking brake lever released (Parking brake SW off) [w/ daytime running light] TAIL RELAY 3–5 : Closed with the light control SW at TAIL or HEAD position D6 DOOR COURTESY SW LH 1–GROUND : Continuity with the front LH door open B8 (A), B9 (B) BODY ECU 15–GROUND : Approx. 12 volts with the ignition SW at ON position 3–GROUND : Continuity with the front LH door open (B) 9–GROUND : Always approx. 12 volts (A) 1–GROUND : Always continuity (A) 2–GROUND : Continuity with the light control SW at HEAD position (A)11–GROUND : Continuity with the light control SW at TAIL or HEAD position : PARTS LOCATION Code B9 See Page B 36 Code F13 See Page D Code 34 See Page J20 37 C13 36 F18 38 J24 A 37 D3 36 J11 37 J25 B 37 D6 38 J12 J13 F11 B 34 F12 C 34 J17 A 37 J27 37 B 37 U1 37 37 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1B See Page Junction Block and Wire Harness (Connector Location) 27 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Panel LH) 2H 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) 2K 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) 1F 2C 2D 2001 PRIUS (EWD414U) LIGHT AUTO TURN OFF : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IA2 42 Engine Room Main Wire and Cowl Wire (Cowl Side Panel LH) IB1 42 Floor Wire and Cowl Wire (Cowl Side Panel LH) ID2 42 Instrument Panel Wire and Cowl Wire (Left Kick Panel) : GROUND POINTS Code See Page Ground Points Location ID 42 Cowl Side Panel LH IG 42 Cowl Side Panel RH 2001 PRIUS (EWD414U) MEMO 2001 PRIUS (EWD414U) INTERIOR LIGHT FROM POWER SOURCE SYSTEM (SEE PAGE 50) L–Y GR–B FROM POWER SOURCE SYSTEM (SEE PAGE 50) GR–B GR–B 15A DOME 7. 5A ECU–B 7 1J L–Y 4 MPD1 G1 GATEWAY ECU MPD2 5 2C 2 2G F 3 2N L–Y GR–L L–Y J27 JUNCTION CONNECTOR 4 2A R–G 11 14 MPX1 E10 ENGINE CONTROL MODULE L–Y F MPX2 13 GR J30 A , J31 B GR–B E A R–G 9 B 15 A 16 A JUNCTION CONNECTOR B8 A , B9 B RCTY DCTY 6 3 6 2L 3 2K D A R–W 13 ID2 D A R–B R–W R–G E B D A R–W R–W IF1 F B IB1 R–W R–W 3 J16 JUNCTION CONNECTOR 4 JUNCTION CONNECTOR OFF ON J12 A , J13 B JUNCTION CONNECTOR DOOR I16 INTERIOR LIGHT 1 1 1 B 1 2K R–W R–B 2 E PCTY 12 A A A 8 2D 8 2K 1 1 J11 JUNCTION CONNECTOR BI W–B 1 D7 DOOR COURTESY SW FRONT RH 1 D6 DOOR COURTESY SW FRONT LH L6 LUGGAGE COMPARTMENT LIGHT SW D9 DOOR COURTESY SW REAR RH 1 B D8 DOOR COURTESY SW REAR LH B W–B J33 JUNCTION CONNECTOR L–Y L–Y 1 2N R–W J30 A , J31 B W–B 2 LCTY 14 A 2 R–W L5 LUGGAGE COMPARTMENT LIGHT L–Y P5 PERSONAL LIGHT 1 LP 7 MPX– W–B MPX+ B BODY ECU R–W D B R–W D B R E A A ID 2001 PRIUS (EWD414U) L–Y GR–B GR–B GR–B 4 MP2+ MPX+ A7 A/C AMPLIFIER GR–B L–Y 3 B 2 B 21 A DOOR GR 11 C10 A , C11 B 14 A L COMBINATION METER 7 2A BR 6 2B IH 2001 PRIUS (EWD414U) INTERIOR LIGHT SERVICE HINTS B8 (A), B9 (B) BODY ECU 3–GROUND : Continuity with front LH door open 6–GROUND : Continuity with rear LH, RH door open (A)14–GROUND : Continuity with front RH door open (B) 9–GROUND : Always approx. 12 volts L6 LUGGAGE COMPARTMENT LIGHT SW 1–GROUND : Closed with the luggage compartment door open : PARTS LOCATION Code See Page A7 Code See Page 36 D9 38 Code See Page J27 B8 A 36 E10 36 J30 J31 37 A 38 B 38 B9 B 36 G1 37 C10 A 36 I16 38 J33 38 C11 B 36 J11 37 L5 38 D6 38 J12 A 37 L6 38 D7 38 J13 B 37 P5 39 D8 38 J16 37 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1J See Page Junction Block and Wire Harness (Connector Location) 27 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Panel LH) 2G 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) 2K 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) 31 Floor Wire and Instrument Panel J/B (Cowl Side Panel LH) 2A 2B 2C 2D 2L 2N : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IB1 42 Floor Wire and Cowl Wire (Cowl Side Panel LH) ID2 42 Instrument Panel Wire and Cowl Wire (Left Kick Panel) IF1 42 Instrument Panel Wire and Floor Wire (Left Kick Panel) : GROUND POINTS Code See Page Ground Points Location ID 42 Cowl Side Panel LH IH 42 Right Kick Panel BI 46 Left Side of Rear Pillar 2001 PRIUS (EWD414U) MEMO 2001 PRIUS (EWD414U) MULTIPLEX COMMUNICATION SYSTEM (COMMUNICATION BUS) GR 16 MPX– B8 BODY ECU MPX+ 13 15 MPX2 GR–B E10 ENGINE CONTROL MODULE MPX1 14 2 MPX+ GR–L C11 COMBINATION METER MPX– 3 11 GR MPD2 G1 GATEWAY ECU MPD1 11 4 MPX+ A7 A/C AMPLIFIER MP2+ 4 GR–B 2001 PRIUS (EWD414U) MEMO 2001 PRIUS (EWD414U) KEY REMINDER AND LIGHT REMINDER BUZZER FROM POWER SOURCE SYSTEM (SEE PAGE 50) W (* 1) 10A GAUGE 1 4 1 3 2 7. 5A ECU–B 5 7. 5A TAIL 2 5 2A 5 2C 3 L 6 2K (* 1) 8 1F R–G 1 1B 1 TAIL RELAY SHORT PIN (* 1) (* 2) HEAD RELAY 2 30A HEAD 1 1 2H (* 2) 2 R–W R–G (* 2) IA2 (* 1) D3 DAYTIME RUNNING J20 LIGHT RELAY JUNCTION CONNECTOR R–G R–G R–G LG 6 6 J27 JUNCTION CONNECTOR (* 2) R–W B W H–LP H F 7 (*1) 2 ID2 E F (*1) LG R–G R–W (* 2) R–W 3 ID2 FUSIBLE LINK BLOCK NO. 1 1 C 100A DC/DC 1 B F11 B , F12 C , F13 D E 2 B 17 11 B HRLY 15 TAIL TRLY 9 B IG 6 ID2 LG–R 13 14 D A R–W R F B OFF C13 LIGHT CONTROL SW [COMB. SW] TAIL 3 IB1 R–W HEAD W–B 16 BATTERY J12 A , J13 B 5 ID2 B8 A , B9 B BODY ECU JUNCTION CONNECTOR 3 1 2K R–W T 18 B LG–R F18 FUSIBLE LINK BLOCK NO. 2 120A MAIN 1 DCTY H 17 B R B–G 1 D 1 A J17 JUNCTION CONNECTOR IG 2001 PRIUS (EWD414U) D6 DOOR COURTESY SW FRONT LH B FROM POWER SOURCE SYSTEM (SEE PAGE 50) * 1 : W/ DAYTIME RUNNING LIGHT * 2 : W/O DAYTIME RUNNING LIGHT 15A DOME 7 1J L–Y L GR–B 4 2A 4 11 GR–L MP2+ 12 KSW 1 B BODY ECU GR–B GR L L 21 A 1 W–B A B W–B A A BUZZER C10 A , C11 B 14 A COMBINATION METER 8 2D 7 2A 8 2K 6 2B W–B B8 A , B9 B 22 A 2 W–B E 3 B L MPX+ 2 B A J11 JUNCTION CONNECTOR ID 2001 PRIUS (EWD414U) BR 15 A MPX– U1 UNLOCK WARNING SW GR–B L–B GR 16 A 9 2C J24 A , J25 B B 13 JUNCTION CONNECTOR B L–B MPX2 11 J27 JUNCTION CONNECTOR MPX1 E10 ENGINE CONTROL MODULE 14 L–B MPX+ A7 A/C AMPLIFIER MPD2 G1 GATEWAY ECU 4 MPD1 GR–B 2 2G IH KEY REMINDER AND LIGHT REMINDER BUZZER SYSTEM OUTLINE The current always flows from GAUGE fuse to body ECU TERMINAL 15. 1. LIGHT REMINDER BUZZER SYSTEM If you open the door of the driver’s side when either headlight or taillight is on with ignition SW being off, the buzzer comes on. 2. KEY REMINDER BUZZER SYSTEM If you open the door of the driver’s side when the ignition key is inserted in ignition SW being off, the buzzer comes on. SERVICE HINTS B8 (A), B9 (B) BODY ECU (B) 9–GROUND : Always approx. 12 volts (A) 1–GROUND : Always continuity 12–GROUND : Continuity with the ignition key in cylinder D6 DOOR COURTESY SW FRONT LH 1–GROUND : Closed with the driver’s door open C10 (A) COMBINATION METER (A)22–GROUND : Approx. 12 volts with the ignition SW at ON position (A)21–GROUND : Always approx. 12 volts (A)14–GROUND : Always continuity : PARTS LOCATION Code See Page A7 Code 36 See Page E10 36 Code J13 See Page B 37 B8 A 36 F11 B 34 J17 B9 B 36 F12 C 34 J20 C10 A 36 F13 D 34 J24 A 37 C11 B 36 F18 38 J25 B 37 C13 36 G1 37 J27 37 D3 36 J11 37 U1 37 D6 38 J12 A 37 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1B 1F 27 Engine g Room Main Wire and Engine g Room J/B (Engine ( g Compartment Left)) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Panel LH) 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) 1J 2A 2B 2C 2D 2G 2H 2K : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IA2 42 Engine Room Main Wire and Cowl Wire (Cowl Side Panel LH) IB1 42 Floor Wire and Cowl Wire (Cowl Side Panel LH) ID2 42 Instrument Panel Wire and Cowl Wire (Left Kick Panel) 2001 PRIUS (EWD414U) 37 37 : GROUND POINTS Code See Page Ground Points Location ID 42 Cowl Side Panel LH IG 42 Cowl Side Panel RH IH 42 Right Kick Panel 2001 PRIUS (EWD414U) J11 JUNCTION CONNECTOR A 3 8 2D 1 10 W–B A A A A IJ1 11 A B A A L L PKBL GR GR–B 4 2A MPX1 MPX2 4 C10 A , C11 B 1 IJ1 ID 2001 PRIUS (EWD414U) L IJ1 IJ1 A7 A/C AMPLIFIER G–O G–O GR–B GR GR–L G1 GATEWAY ECU E10 ENGINE CONTROL MODULE 13 SEAT BELT (FRONT PASSENGER’ S SEAT) 8 GR–B 5 B SEAT BELT (DRIVER’ S SEAT) 3 B G–O DBKL D B 6 2B E A BR 9 J29 JUNCTION CONNECTOR G–O B8 A , B9 B B20 BUCKLE SW LH MPX+ W–B 15 A J22 A , J23 B BODY ECU P–L MPX– B21 BUCKLE SW RH AND SEAT BELT WARNING OCCUPANT DETECTION SENSOR P–L 16 A JUNCTION CONNECTOR W–B W–B IG JUNCTION CONNECTOR W–B W–B 15 J24 A , J25 B W–B 5 2A 2 14 A COMBINATION METER 8 2K 7 2A W–B IH L–Y L SEAT BELT WARNING FROM POWER SOURCE SYSTEM (SEE PAGE 50) 10A GAUGE 15A DOME 7 1J GR–L 11 MPD2 MPD1 14 4 2 2G MP2+ 11 MPX+ 2 B 3 B 22 A 21 A SYSTEM OUTLINE When the driver has not fastened the seat belt while the ignition SW is ON, the driver seat belt warning light blinks, and a warning buzzer comes on. Also, in the front passenger seat, a sensor recognizes a passenger, and when the passenger has not fastened the seat belt, the front passenger seat belt warning light blinks. SERVICE HINTS B20 BUCKLE SW LH 1–2 : Closed with driver’s seat belt in use : PARTS LOCATION Code See Page A7 Code See Page Code See Page 36 C10 A 36 J22 A 37 C11 B B8 A 36 36 J23 B 37 B9 B 36 E10 36 J24 A 37 B20 38 G1 37 J25 B 37 B21 38 J11 37 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1J See Page J29 Junction Block and Wire Harness (Connector Location) 27 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl ( Side Panel LH)) 2G 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) 2K 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) 2A 2B 2D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IJ1 See Page 44 Joining Wire Harness and Wire Harness (Connector Location) Floor No.3 Wire and Instrument Panel Wire (Under the Instrument Panel Center) : GROUND POINTS Code See Page Ground Points Location ID 42 Cowl Side Panel LH IH 42 Right Kick Panel 2001 PRIUS (EWD414U) 37 WIPER AND WASHER FROM POWER SOURCE SYSTEM (SEE PAGE 50) 6 2I 3 2G L L 2 2N 30A WIPER L 15A WASHER WF WIPER SW W1 WASHER MOTOR L 10 IH1 EW 2 WASHER SW OFF M HI LO INT 1 WF E 11 L–Y 2 IA1 L–Y 2 INT1 W–B INT2 B1 OFF ON L–W +1 7 L–B +2 8 L–R +B 17 L +S 16 A 15 IA1 L–W 17 IA1 L W–B J18 JUNCTION CONNECTOR IA1 L–B 16 C12 FRONT WIPER AND WASHER SW [COMB. SW] L–R 3 5 2 1 +2 +1 +B +S A W–B M E F9 FRONT WIPER MOTOR 4 W–B W–B +B +2 +1 +S A J17 JUNCTION CONNECTOR A IG 2001 PRIUS (EWD414U) A IE J1 JUNCTION CONNECTOR A J7 JUNCTION CONNECTOR SYSTEM OUTLINE When the ignition SW is turned ON, the current flows from WIPER fuse to wiper and washer SW TERMINAL 17 and front wiper motor TERMINAL 2 or the current flows from WASHER fuse to washer motor TERMINAL 2. 1. LO POSITION When the wiper and washer SW is at LO position, the current flows from wiper and washer SW TERMINAL 17 to TERMINAL 7 to front wiper motor TERMINAL 5 to TERMINAL 4 to GROUND, and the front wiper motor runs at low speed. 2. HI POSITION When the wiper and washer SW is at HI position, the current flows from wiper and washer SW TERMINAL 17 to TERMINAL 8 to front wiper motor TERMINAL 3 to TERMINAL 4 to GROUND, and the front wiper motor runs at high speed. 3. INT POSITION When the wiper and washer SW is at INT position, the wiper relay is activated and the current flows from wiper and washer SW TERMINAL 17 to TERMINAL 2 to GROUND. This current activates the intermittent circuit, and the current flows from wiper and washer SW TERMINAL 17 to TERMINAL 7 to front wiper motor TERMINAL 5 to TERMINAL 4 to GROUND, and operates the front wipers. 4. WASHER CONTINUOUS OPERATION When the wiper and washer SW is pulled to WASHER position (Washer SW ON position), the current from the WASHER fuse flows to washer motor TERMINAL 2 to TERMINAL 1 to wiper and washer SW TERMINAL 11 to TERMINAL 2 to GROUND, and operates the washer motor to emit a water spray. At the same time, the current flows from the WIP fuse to wiper and washer SW TERMINAL 17 to TERMINAL 7 to front wiper motor TERMINAL 5 to TERMINAL 4 to GROUND, and operates the front wiper motor. SERVICE HINTS C12 FRONT WIPER AND WASHER SW 2–GROUND : Always continuity 7–GROUND : Approx. 12 volts with the front wiper and washer SW at LO position Approx. 2 to 12 seconds intermittently with the front wiper and washer SW at INT position 8–GROUND : Approx. 12 volts with the front wiper and washer SW at HI position 16–GROUND : Approx. 12 volts with the ignition SW on unless the front wiper motor at STOP position 17–GROUND : Approx. 12 volts the ignition SW at ON or ST position F9 FRONT WIPER MOTOR 2–1 : Closed unless the wiper motor at STOP position : PARTS LOCATION Code See Page Code See Page C12 36 J7 37 F9 34 J17 37 J1 37 J18 37 Code ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 2G 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) 2I 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) 2N 31 Floor Wire and Instrument Panel J/B (Cowl Side Panel LH) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IA1 42 Engine Room Main Wire and Cowl Wire (Cowl Side Panel LH) IH1 42 Floor Wire and Engine Room Main Wire (Left Kick Panel) : GROUND POINTS Code See Page Ground Points Location IE 42 Cowl Side Panel LH IG 42 Cowl Side Panel RH 2001 PRIUS (EWD414U) W1 See Page 35 CIGARETTE LIGHTER FROM POWER SOURCE SYSTEM (SEE PAGE 50) 15A CIG GR 5 2D 2 C8 CIGARETTE LIGHTER W–B 1 A J24 JUNCTION CONNECTOR W–B A 8 2D W–B 8 2K A J11 JUNCTION CONNECTOR ID 2001 PRIUS (EWD414U) SERVICE HINTS C8 CIGARETTE LIGHTER 2–GROUND : Approx. 12 volts with the ignition SW at ACC or ON position 1–GROUND : Always continuity : PARTS LOCATION Code See Page C8 36 Code J11 See Page 37 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 2D 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Panel LH) 2K 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) : GROUND POINTS Code ID See Page 42 Ground Points Location Cowl Side Panel LH 2001 PRIUS (EWD414U) Code J24 See Page 37 HORN FROM POWER SOURCE SYSTEM (SEE PAGE 50) 10A HORN 1 5 HORN RELAY 2 1J 9 1F B–W 3 B–R 2 IA2 1 H4 HORN B–R 8 D J20 JUNCTION CONNECTOR B–R D 6 C14 HORN SW [COMB. SW] 2001 PRIUS (EWD414U) SERVICE HINTS HORN RELAY 5–3 : Closed with the horn SW on : PARTS LOCATION Code See Page C14 36 Code H4 See Page 34 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1F 1J See Page 27 IA2 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) See Page 42 J20 Junction Block and Wire Harness (Connector Location) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code Code Joining Wire Harness and Wire Harness (Connector Location) Engine Room Main Wire and Cowl Wire (Cowl Side Panel LH) 2001 PRIUS (EWD414U) See Page 37 POWER WINDOW FROM POWER SOURCE SYSTEM (SEE PAGE 50) B8 A , B9 B 1 15A DOME 20A PWR1 10A GAUGE BODY ECU 30A POWER 7. 5A ECU–B IG 2 B 9 B 15 RX DCTY 6 A 3 1 2K 5 2C 2 2G R–L W–R L–Y POWER RELAY 2 J27 JUNCTION CONNECTOR F F R–W 10 2K Y 11 2J R–G 7 1J 5 R–G 1 3 3 2I L–W L–W 7 2K Y 2 1 IC1 7 IC1 1 J14 A , J15 B 2 F B M D4 DIODE (DOOR COURTESY) D A 1 R–W 3 D A R–W P10 POWER WINDOW MOTOR FRONT LH R–W A W–B J16 JUNCTION CONNECTOR 3 IB1 R–W A A R–W LIMIT SW DCTY 16 J12 A , J13 B G 5 E 9 R–Y 8 P9 POWER WINDOW MASTER SW R–Y 20 MPX1 W–B 11 4 18 DU 13 O DDN 12 P–L SGND 2 WLSW GR LMT IG JUNCTION CONNECTOR 4 B R–W R–L 1 5 IG1 Y W–R 5 CPUB 2 IC1 B–L L–Y L–Y 8 IC1 PULSE SENSOR A A L–W 3 IC1 3 A A JUNCTION CONNECTOR C 1 IG1 PLS C B L–W J20 JUNCTION CONNECTOR C B R–L C B C B–L B A JUNCTION CONNECTOR J24 A , J25 B L–Y 4 2D 1 J17 JUNCTION CONNECTOR IG 2001 PRIUS (EWD414U) 1 D7 DOOR COURTESY SW FRONT RH D6 DOOR COURTESY SW FRONT LH B8 A , B9 B BODY ECU FLU FLD RRD RLU 14 RRU 1 5 10 10 2J 5 2K 2 2L 1 2L 2 A RLD E 1 B W–B 3 A L–W L–W IB1 L–O G–R 8 2D L–W B–W W L–W G–B R–W 7 8 2K 7 IN1 5 IN1 5 BB1 3 BB1 4 BB1 5 BA1 3 BA1 4 BA1 R–W G–B L–W W B–W L–W L–O G–R W–B 3 IQ1 L–W L–W A 5 Y D P8 POWER WINDOW CONTROL SW REAR RH 2 1 BB1 M 5 P13 POWER WINDOW MOTOR REAR RH D P7 POWER WINDOW CONTROL SW REAR LH 1 1 BA1 SD U 3 J17 JUNCTION CONNECTOR A E 2 1 1 SU 2 G 3 1 P11 POWER WINDOW MOTOR FRONT RH U 2 6 PCT M 2 P12 POWER WINDOW MOTOR REAR LH W–B W–B 1 IQ1 M E 4 SD W–B 2 1 SU W–B D P6 POWER WINDOW CONTROL SW FRONT RH 6 PCT G 5 Y U 3 W–B E 4 SD Y 1 SU W–B 6 PCT G 4 J11 JUNCTION CONNECTOR W–B IG BI 2001 PRIUS (EWD414U) A ID POWER WINDOW SYSTEM OUTLINE Communication between power window master SW and body ECU is controlled and body ECU recognizes the conditions of each SW to control the operation of windows. 1. MANUAL UP OR DOWN OPERATION (DRIVER’S WINDOW, PASSENGER’S WINDOW) During you are pushing power window master SW (Driver side) halfway down, the motor operates and the window on the driver’s side opens. During you are pulling power window master SW (Driver side) halfway up, the motor operates and the windows on the driver’s side closes. The window on the passenger’s side opens or closes by pushing down or pulling up power window master SW (Front passenger, rear passenger) or power window SW front RH, rear LH, RH. 2. AUTO UP OR DOWN OPERATION (DRIVER’S WINDOW) When the power window master SW (Driver side) is fully pushed down, the motor operates and the window on the driver’s side automatically opens. When the power window master SW (Driver side) is fully pulled up, the motor operates and the window on the driver’s side automatically closes. 3. STOPPING AUTOMATIC WINDOW OPERATION If you push the power window master SW (Driver side) halfway down during the window on the driver’s side is raising automatically, the motor’s operation stops. And if you pull the power window master SW (Driver side) halfway up during the window on the driver’s side is lowering automatically, the motor’s operation stops. 4. KEY OFF POWER WINDOW OPERATION After the Ignition SW is turned off, the windows can be operated for about 43 seconds. However, the window operation stops when either front doors opens. 5. JAM PROTECTION FUNCTION (DRIVER’S WINDOW) When any foreign object gets caught during power window UP operation, the motor rotates in the opposite direction to open the window. SERVICE HINTS P9 POWER WINDOW MASTER SW 1–GROUND : Always approx. 12 volts 4–GROUND : Approx. 12 volts with the ignition SW at ON position 9–GROUND : Always continuity B8 (A), B9 (B) BODY ECU 15–GROUND : Approx. 12 volts with the ignition SW at ON position (B)9–GROUND : Always approx. 12 volts : PARTS LOCATION Code B8 B9 See Page A 36 B Code J15 See Page B Code See Page 37 P7 39 36 J16 37 P8 39 D4 36 J17 37 P9 39 D6 38 J20 37 P10 39 D7 38 J24 A 37 P11 39 J25 B 37 P12 39 P13 39 J12 A 37 J13 B 37 J27 37 J14 A 37 P6 39 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1J 2C 2D 2G See Page Junction Block and Wire Harness (Connector Location) 27 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Panel LH) 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) 31 Cowl Wire and Instrument Panel J/B ((Cowl Side Panel LH)) 31 Floor Wire and Instrument Panel J/B (Cowl Side Panel LH) 2I 2J 2K 2L 2001 PRIUS (EWD414U) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IB1 42 Floor Wire and Cowl Wire (Cowl Side Panel LH) IC1 42 Front Door LH Wire and Cowl Wire (Left Kick Panel) IG1 42 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) IN1 44 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IQ1 44 Front Door RH Wire and Cowl Wire (Right Kick Panel) BA1 46 Rear Door No.2 Wire and Floor Wire (Center Pillar LH) BB1 46 Rear Door No.1 Wire and Cowl Wire (Center Pillar RH) : GROUND POINTS Code See Page Ground Points Location IG 42 Cowl Side Panel RH BI 46 Left Side of Rear Pillar 2001 PRIUS (EWD414U) REMOTE CONTROL MIRROR FROM POWER SOURCE SYSTEM (SEE PAGE 50) 10A ACC GR–R 2 2D C J27 JUNCTION CONNECTOR GR–R C R5 REMOTE CONTROL MIRROR SW 8 5 OPERATION SW RIGHT/ DOWN LEFT/ UP M+ E 2 HR 6 7 R–G L LG SELECT SW HL 3 W–B VR 4 BR–R MH W MV VL RIGHT LEFT UP DOWN B A B J24 A , J25 B JUNCTION CONNECTOR A A A J26 JUNCTION CONNECTOR A W R–G BR–R 9 IN1 8 IN1 10 IN1 R–G BR–R 8 2K 3 1 5 3 W–B 5 10 IG1 W LG 1 BR–R LG 8 IG1 BR–R L 9 IG1 L A W–B BR–R 8 2D M M M M A J11 JUNCTION CONNECTOR R10 REMOTE CONTROL MIRROR LH R11 REMOTE CONTROL MIRROR RH 2001 PRIUS (EWD414U) ID SERVICE HINTS R5 REMOTE CONTROL MIRROR SW 8–GROUND : Approx. 12 volts with the ignition SW at ACC or ON position 6–7 : Continuity with the operation SW at UP or LEFT position 8–6 : Continuity with the operation SW at DOWN or RIGHT position : PARTS LOCATION Code See Page J11 Code See Page 37 R10 39 R11 39 A 37 J27 37 J25 B 37 R5 37 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, See Page Junction Block and Wire Harness (Connector Location) 2D 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Panel LH) 2K 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IG1 42 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) IN1 44 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) : GROUND POINTS Code ID See Page 42 See Page J26 J24 Code Code 37 Ground Points Location Cowl Side Panel LH 2001 PRIUS (EWD414U) SHIFT LOCK FROM POWER SOURCE SYSTEM (SEE PAGE 50) 15A STOP 10A ACC 2 2D 2 2I B–Y GR–R R–B 9 2K 5A ECU–IG 1 D A S3 STOP LIGHT SW C A J27 A , J28 B D A G–W B–Y JUNCTION CONNECTOR 2 J14 A JUNCTION CONNECTOR C B E A 5 ID1 B–Y JUNCTION CONNECTOR G–W D B GR–R J14 A , J15 B B 1 ID2 B D D G–W GR–R B–Y J26 JUNCTION CONNECTOR 6 1 3 STP ACC J21 JUNCTION CONNECTOR IG P1 P P2 R 3 B 2 Y 1 LOCK FREE SHIFT LOCK CONTROL SW SLS+ SLS– E L–R B S2 SHIFT LOCK ECU L W–B 4 4 A B J24 A , J25 B A A A A 3 W–B W–B W–B JUNCTION CONNECTOR E 8 2D U1 KEY INTERLOCK SOLENOID [UNLOCK WARNING SW] J21 JUNCTION CONNECTOR W–B W–B E 8 2K D B J11 JUNCTION CONNECTOR E A ID J22 A , J23 B JUNCTION CONNECTOR A W–B 2001 PRIUS (EWD414U) 2 SHIFT LOCK SOLENOID KLS+ 5 1 SYSTEM OUTLINE When the ignition SW is turned to ACC position the current from the ACC fuse flows to TERMINAL 1 of the shift lock ECU, in the ON position, the current from the ECU–IG fuse flows to TERMINAL 3 of the ECU. 1. SHIFT LOCK MECHANISM With the ignition SW on, when a signal that the brake pedal is depressed (Stop light SW on) and a signal that the shift lever is put in P position (Continuity between P1 and P of the shift lock control SW) is input to the ECU, the ECU operates and current flows from TERMINAL 3 of the ECU to TERMINAL SLS+ of the shift lock solenoid to solenoid to TERMINAL SLS– to TERMINAL 5 of the ECU to GROUND. This causes the shift lock solenoid to turn on (Plate stopper disengages) and the shift lever can shift into position other than the P. 2. KEY INTERLOCK MECHANISM With the ignition SW ON or ACC position, when the shift lever is put in P position (No continuity between P2 and P of shift lock control SW), the current flowing from TERMINAL 4 of the ECU to the key interlock solenoid is cut off. This causes the key interlock solenoid to turn off (Lock lever disengages from LOCK position) and the ignition key can be turned from ACC to LOCK position. SERVICE HINTS S2 SHIFT LOCK ECU 1–GROUND : Approx. 12 volts with the ignition SW at ACC or ON position 3–GROUND : Approx. 12 volts with the ignition SW at ON position 5–GROUND : Always continuity 6–GROUND : Approx. 12 volts with the brake pedal depressed S3 STOP LIGHT SW 2–1 : Closed with the brake pedal depressed : PARTS LOCATION Code See Page J11 J14 J15 See Page J23 B 37 A 37 J24 A 37 B 37 J25 B J21 J22 Code 37 37 A J26 37 J27 A Code J28 2D 2I 2K See Page 37 37 S3 37 37 U1 37 37 Junction Block and Wire Harness (Connector Location) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Panel LH) 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code ID1 ID2 See Page 42 Joining Wire Harness and Wire Harness (Connector Location) Instrument Panel Wire and Cowl Wire (Left Kick Panel) : GROUND POINTS Code ID See Page 42 37 S2 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page B Ground Points Location Cowl Side Panel LH 2001 PRIUS (EWD414U) DOOR LOCK CONTROL FROM POWER SOURCE SYSTEM (SEE PAGE 50) 15A DOME 30A DOOR 10A GAUGE 5 2C L–Y 7 1J 7. 5A ECU–B B8 A , B9 B 8 IG B KSW LUG 9 B 5 A J27 JUNCTION CONNECTOR J27 JUNCTION CONNECTOR IF1 B A J24 A , J25 B JUNCTION CONNECTOR W–B B 2 L–Y 2 R U1 UNLOCK WARNING SW L–B 1 1 A A A A W–B W–B J24 A , J25 B JUNCTION CONNECTOR A B B 8 2D 8 2K W–B 1 D9 DOOR COURTESY SW REAR RH W–B B W–B J33 JUNCTION CONNECTOR W–B W–B L4 LUGGAGE COMPARTMENT DOOR UNLOCK SW B L–B C B L–Y 3 2K R–G 2 L–Y 6 2L L–B L–Y F F 1 IG1 6 L–B R–G 9 2C 4 2D RCTY E 1 B 12 D8 DOOR COURTESY SW REAR LH R–G B 2 2G BODY ECU 15 1 A J11 JUNCTION CONNECTOR BJ W–B ID 2001 PRIUS (EWD414U) B8 A , B9 B BODY ECU PCTY RX 1 2K ACTD 6 A 10 B Y 3 R–W DCTY 12 A G 5 IG1 Y 13 ID2 18 P9 POWER WINDOW MASTER SW R–W 3 IB1 G 1 2 M W–B R–W 3 1 2 IG1 W–B D6 DOOR COURTESY SW FRONT LH D7 DOOR COURTESY SW FRONT RH 4 G 5 R 6 5 IC1 R R–W 3 D4 DIODE (DOOR COURTESY) 1 7 IG1 LOCK A D A UNLOCK R–W J16 JUNCTION CONNECTOR A R–W 2 R–W D A R–Y J12 A , J13 B 1 LSWD 10 7 IC1 JUNCTION F B CONNECTOR A KL 6 R–Y L–Y R–W L–Y KUL 15 W DCTY 16 5 G–Y CPUB L–B R–W MPX1 W–B 2001 PRIUS (EWD414U) D13 DOOR LOCK MOTOR, DOOR KEY LOCK AND UNLOCK SW AND DOOR UNLOCK DETECTION SW FRONT LH DOOR LOCK CONTROL B8 A , B9 B BODY ECU L2 7 B LSWP ACT+ 17 A ACT– 9 16 4 2I 1 2J LSR 18 A 8 2L 9 2L W–L UL2 16 B G B A B A JUNCTION CONNECTOR A B B B A B B B R G W–L W G L–B C A J22 A , J23 B J14 A , J15 B C A JUNCTION CONNECTOR W–L G R G W–L 12 ID2 B B G R 5 IQ1 6 IQ1 2 BB1 6 BB1 7 BB1 2 BA1 6 BA1 7 BA1 W G R G R W–L G R W–L 1 2 3 6 5 4 3 1 2 1 4 D12 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR RH 2 D11 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR LH 1 BB1 7 IQ1 3 W–B W–B W–B W–B A B M W–B W–B M W–B UNLOCK LOCK D14 DOOR LOCK MOTOR, DOOR KEY LOCK AND UNLOCK SW AND DOOR UNLOCK DETECTION SW FRONT RH 4 W–L R 2 IN1 W–L G 12 IN1 G IF1 L–B 1 11 IN1 M B A A B J18 A , J19 B 1 BA1 W–B JUNCTION CONNECTOR A A A J17 JUNCTION CONNECTOR A W–B IG 2001 PRIUS (EWD414U) BI B8 A , B9 B BODY ECU L1 UL1 R–B 1 IN1 6 IN1 R–B 6 5 LOCK UNLOCK G–B 15 B G–B 14 B D10 DOOR LOCK CONTROL SW FRONT RH W–B 3 2 IQ1 W–B 2001 PRIUS (EWD414U) DOOR LOCK CONTROL SYSTEM OUTLINE The current is always sent from DOOR fuse to TERMINAL B of body ECU. When ignition SW is turned on, the current is sent from GAUGE fuse to TERMINAL IG of the body ECU. 1. MANUAL LOCK OPERATION When the door lock control SW (Power window master SW) is turned to LOCK position, the lock signal from TERMINAL MPX1 of power window master SW is input to TERMINAL RX of body ECU to operate ECU. The current is sent from TERMINAL ACT+ of ECU to each motor and the motor locks the doors by the current sent from TERMINAL ACT– of ECU to GROUND. 2. MANUAL UNLOCK OPERATION When the door lock control SW (Power window master SW) is turned to UNLOCK position, the unlock signal from TERMINAL MPX1 of power window master SW is input to TERMINAL RX of body ECU to operate ECU. The current is sent from TERMINAL ACT– of ECU to each motor and the motor unlocks the doors by the current sent from TERMINAL ACT+ of ECU to GROUND. 3. DOOR KEY LOCK AND UNLOCK OPERATION ∗ Lock operation from the driver’s side door When the driver’s side door is locked using the ignition key, all the doors are locked. ∗ Unlock operation from the driver’s side door When the driver’s side door is unlocked once using the ignition key, only the driver’s side door is unlocked. If this operation is repeated within 3 seconds, all the other doors are unlocked. ∗ Lock operation from the front passenger’s side door When the front passenger’s side door is locked using the ignition key, all the doors are locked. ∗ Unlock operation from the front passenger’s side door When the front passenger’s side door is unlocked using the ignition key, all the doors are unlocked SERVICE HINTS B8 (A), B9 (B) BODY ECU 15–GROUND : Approx. 12 volts with the ignition SW at ON position 8–GROUND : Always approx. 12 volts (B) 1–GROUND : Always continuity D6, D7, D8, D9 DOOR COURTESY SW FRONT LH, RH, REAR LH, RH 1–GROUND : Closed with each of the door open U1 UNLOCK WARNING SW 1–2 : Closed with the ignition key in the cylinder : PARTS LOCATION Code See Page Code See Page Code See Page B8 A 36 D13 38 J19 B 37 B9 B 36 D14 38 J22 A 37 D4 36 J11 37 J23 B 37 D6 38 J12 A 37 J24 A 37 D7 38 J13 B 37 J25 B 37 D8 38 J14 A 37 J27 37 D9 38 J15 B 37 J33 38 D10 38 J16 37 L4 38 D11 38 J17 37 P9 39 D12 38 37 U1 37 J18 A 2001 PRIUS (EWD414U) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1J 2C 2D 2G See Page Junction Block and Wire Harness (Connector Location) 27 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Panel LH) 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) 31 Cowl Wire and Instrument Panel J/B ((Cowl Side Panel LH)) 31 Floor Wire and Instrument Panel J/B (Cowl Side Panel LH) 2I 2J 2K 2L : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IB1 42 Floor Wire and Cowl Wire (Cowl Side Panel LH) IC1 42 Front Door LH Wire and Cowl Wire (Left Kick Panel) ID2 42 Instrument Panel Wire and Cowl Wire (Left Kick Panel) IF1 42 Instrument Panel Wire and Floor Wire (Left Kick Panel) IG1 42 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) IN1 44 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IQ1 44 Front Door RH Wire and Cowl Wire (Right Kick Panel) BA1 46 Rear Door No.2 Wire and Floor Wire (Center Pillar LH) BB1 46 Rear Door No.1 Wire and Cowl Wire (Center Pillar RH) : GROUND POINTS Code See Page Ground Points Location ID 42 Cowl Side Panel LH IG 42 Cowl Side Panel RH BI 46 Left Side of Rear Pillar BJ 46 Right Side of Rear Pillar 2001 PRIUS (EWD414U) WIRELESS DOOR LOCK CONTROL FROM POWER SOURCE SYSTEM (SEE PAGE 50) 15A DOME 7 1J 7. 5A ECU–B 30A DOOR 10A GAUGE L–Y 5 2C B8 A , B9 B 8 B 9 B IG PRG 7 A RDA KSW 8 A E L–B IF1 B L–B B L–B E W5 WIRELESS DOOR CONTROL RECEIVER L–Y W–B 1 2 R 2 RDA R–G 3 PRG 1 2 1 E B W–B J33 JUNCTION CONNECTOR J24 A , J25 B JUNCTION CONNECTOR A B A A A A A A W–B W–B W–B 8 2K 1 D9 DOOR COURTESY SW REAR RH 8 2D B B W–B W–B W–B JUNCTION CONNECTOR E B W–B J23 B W–B L–Y D8 DOOR COURTESY SW REAR LH +B U1 UNLOCK WARNING SW L–Y 5 1 IG1 3 2K W–B L–B R–G J24 A , J25 B JUNCTION CONNECTOR C B 6 2L 2 F B A LUG 5 A 6 L B–R J27 JUNCTION CONNECTOR F J27 JUNCTION CONNECTOR L–Y F R–G 9 2C 4 2D RCTY 1 B 12 L4 LUGGAGE COMPARTMENT DOOR UNLOCK SW R–G B 2 2G BODY ECU 15 1 A J11 JUNCTION CONNECTOR W–B ID 2001 PRIUS (EWD414U) BJ B8 A , B9 B BODY ECU PCTY RX DCTY 12 A ACTD 6 A 10 B Y 3 R–W 1 2K G Y 5 IG1 13 ID2 18 P9 POWER WINDOW MASTER SW KUL 16 R–W A 6 5 5 IC1 1 2 R–W LOCK A 3 IB1 M W–B R–W 1 2 IG1 W–B D6 DOOR COURTESY SW FRONT LH R–W 3 D7 DOOR COURTESY SW FRONT RH 4 G R–W 3 7 IG1 G 1 UNLOCK A D A R–W R–W D A R L–Y R 2 D4 DIODE (DOOR COURTESY) R–Y J12 A , J13 B J16 JUNCTION CONNECTOR 10 7 IC1 JUNCTION F B CONNECTOR 1 LSWD 6 R–Y L–Y KL 15 W 5 G–Y DCTY CPUB L–B R–W MPX1 W–B 2001 PRIUS (EWD414U) D13 DOOR LOCK MOTOR, DOOR KEY LOCK AND UNLOCK SW AND DOOR UNLOCK DETECTION SW FRONT LH WIRELESS DOOR LOCK CONTROL B8 A , B9 B BODY ECU L2 LSWP 7 B ACT+ 17 A ACT– 9 16 4 2I 1 2J LSR 18 A 8 2L 9 2L W–L UL2 16 B G B A B A JUNCTION CONNECTOR A B B B A B B B R G W–L W G L–B C A J22 A , J23 B J14 A , J15 B C A JUNCTION CONNECTOR W–L G R G W–L 12 ID2 B B G R 5 IQ1 6 IQ1 2 BB1 6 BB1 7 BB1 2 BA1 6 BA1 7 BA1 W G R G R W–L G R W–L 1 2 3 6 5 4 3 1 2 1 4 D12 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR RH 2 D11 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR LH 1 BB1 7 IQ1 3 W–B W–B W–B W–B A B M W–B W–B D14 DOOR LOCK MOTOR, DOOR KEY LOCK AND UNLOCK SW AND DOOR UNLOCK DETECTION SW FRONT RH M W–B LOCK UNLOCK 4 W–L R 2 IN1 W–L G 12 IN1 G IF1 L–B 1 11 IN1 M B A A B J18 A , J19 B 1 BA1 W–B JUNCTION CONNECTOR A A A J17 JUNCTION CONNECTOR A W–B IG 2001 PRIUS (EWD414U) BI B8 A , B9 B BODY ECU L1 UL1 R–B 1 IN1 6 IN1 R–B 6 5 LOCK UNLOCK G–B 15 B G–B 14 B D10 DOOR LOCK CONTROL SW FRONT RH W–B 3 2 IQ1 W–B 2001 PRIUS (EWD414U) WIRELESS DOOR LOCK CONTROL SYSTEM OUTLINE The current is always sent from DOOR fuse to TERMINAL B of body ECU. At the same time, the current is always sent from DOME fuse to TERMINAL CPUB of power window master SW, and from ECU–B fuse to wireless door lock receiver. When ignition SW is turned on, the current is sent from GAUGE fuse to TERMINAL IG of body ECU. 1. WIRELESS DOOR LOCK OR UNLOCK NORMAL OPERATION ∗ Lock operation When the LOCK SW of the transmitter is pushed, all the doors are locked. ∗ Unlock operation When the UNLOCK SW of the transmitter is pushed, all the doors are unlocked. 2. AUTOMATIC LOCK OPERATION After all the doors are unlocked by pushing the UNLOCK SW of the transmitter, unless each of the doors is opened or the ignition key is inserted, all the doors are locked again. 3. VISUAL CONFIRMATION OF LOCK OR UNLOCK FUNCTION When doors are locked by using the transmitter, the taillight and parking lights blink once. When doors are unlocked by using the transmitter, the taillights and parking lights blink twice. If UNLOCK SW of the transmitter is pushed while all the doors are locked, doors are unlocked and the room lights are turned on simultaneously. 4. WIRELESS CONTROL STOP FUNCTION If the following situations occur, wireless door lock function does not operate. ∗ When each of the doors opens. (Door courtesy SW is on) ∗ When ignition key is inserted to ignition SW. (Unlock warning SW is on) ∗ When ignition SW is on. 5. REPEAT FUNCTION If the doors are not locked after the lock signal is out put from transmitter by pushing LOCK SW, the lock signal is sent again to lock the doors. 6. PANIC MODE FUNCTION When the panic SW of the transmitter is pushed, the horn comes on, and the headlight and taillight flashes. SERVICE HINTS B8 (A), B9 (B) BODY ECU 15–GROUND : Approx. 12 volts with the ignition SW at ON position 8–GROUND : Always approx. 12 volts (B) 1–GROUND : Always continuity W5 WIRELESS DOOR LOCK CONTROL RECEIVER 5–GROUND : Always approx. 12 volts 1–GROUND : Always continuity U1 UNLOCK WARNING SW 2–1 : Closed with the ignition key in the cylinder : PARTS LOCATION Code B8 B9 See Page A 36 B 36 Code See Page D14 J11 Code See Page 38 J23 B 37 37 J24 A 37 D4 36 J12 A 37 J25 B 37 D6 38 J13 B 37 J27 37 D7 38 J14 A 37 J33 38 D8 38 J15 B 37 L4 38 D9 38 J16 37 P9 39 D10 38 J17 37 U1 37 D11 38 J18 A 37 W5 37 D12 38 J19 B 37 D13 38 J22 A 37 2001 PRIUS (EWD414U) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1J 2C 2D 2G See Page Junction Block and Wire Harness (Connector Location) 27 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Panel LH) 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) 31 Cowl Wire and Instrument Panel J/B ((Cowl Side Panel LH)) 31 Floor Wire and Instrument Panel J/B (Cowl Side Panel LH) 2I 2J 2K 2L : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IB1 42 Floor Wire and Cowl Wire (Cowl Side Panel LH) IC1 42 Front Door LH Wire and Cowl Wire (Left Kick Panel) ID2 42 Instrument Panel Wire and Cowl Wire (Left Kick Panel) IF1 42 Instrument Panel Wire and Floor Wire (Left Kick Panel) IG1 42 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) IN1 44 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IQ1 44 Front Door RH Wire and Cowl Wire (Right Kick Panel) BA1 46 Rear Door No.2 Wire and Floor Wire (Center Pillar LH) BB1 46 Rear Door No.1 Wire and Cowl Wire (Center Pillar RH) : GROUND POINTS Code See Page Ground Points Location ID 42 Cowl Side Panel LH IG 42 Cowl Side Panel RH BI 46 Left Side of Rear Pillar BJ 46 Right Side of Rear Pillar 2001 PRIUS (EWD414U) THEFT DETERRENT FROM POWER SOURCE SYSTEM (SEE PAGE 50) 15A DOME 7. 5A ECU–B 10A GAUGE 5 2C L–Y 7 1J 30A DOOR B8 A , B9 B 8 2 2G R–G B 4 2D BODY ECU 15 IG KSW LUG B 5 A 6 6 2L 3 2K L–B W–B L–B R–G J27 JUNCTION CONNECTOR J27 JUNCTION CONNECTOR F 2 IF1 B L–B L–B 1 IG1 B A A A A W–B W–B J24 A , J25 B A B JUNCTION CONNECTOR W–B R 1 1 B R–G 2 W–B 2 8 2D 8 2K W–B 1 D9 DOOR COURTESY SW REAR RH W–B B W–B J33 JUNCTION CONNECTOR U1 UNLOCK WARNING SW L–Y L4 LUGGAGE COMPARTMENT DOOR KEY UNLOCK SW L–Y D8 DOOR COURTESY SW REAR LH J24 A , J25 B F L–Y C B 9 2C JUNCTION CONNECTOR B A RCTY E 1 B 12 L–Y 9 B 1 A J11 JUNCTION CONNECTOR BJ W–B ID 2001 PRIUS (EWD414U) FROM POWER SOURCE SYSTEM (SEE PAGE 50) 7. 5A OBDII W–L J26 JUNCTION CONNECTOR D D 9 2D W–L B8 A , B9 B BODY ECU 11 A BDR PCTY RX 1 2K ACTD 6 A 10 B Y 3 R–W DCTY 12 A G 5 IG1 Y 13 ID2 18 P9 POWER WINDOW MASTER SW KUL KL 6 10 R–Y R–W L–Y R–W 3 IB1 G 1 2 M W–B R–W 3 1 2 IG1 W–B D6 DOOR COURTESY SW FRONT LH 1 4 G 5 R 6 5 IC1 R R–W 3 7 IG1 LOCK A 1 UNLOCK J16 JUNCTION CONNECTOR A R–W R–W A D A R–W D A 2 D4 DIODE (DOOR COURTESY) J12 A , J13 B R–Y 7 IC1 JUNCTION F B CONNECTOR D7 DOOR COURTESY SW FRONT RH LSWD 15 W DCTY 16 5 G–Y CPUB L–B R–W MPX1 W–B 2001 PRIUS (EWD414U) D13 DOOR LOCK MOTOR, DOOR KEY LOCK AND UNLOCK SW AND DOOR UNLOCK DETECTION SW FRONT LH THEFT DETERRENT B8 A , B9 B BODY ECU L2 7 B LSWP ACT+ 17 A ACT– 9 16 4 2I 1 2J LSR 18 A 8 2L 9 2L W–L UL2 16 B G B A B A JUNCTION CONNECTOR A B B B A B B B R G W–L W G L–B C A J22 A , J23 B J14 A , J15 B C A JUNCTION CONNECTOR W–L G R G W–L 12 ID2 B B G R 5 IQ1 6 IQ1 2 BB1 6 BB1 7 BB1 2 BA1 6 BA1 7 BA1 W G R G R W–L G R W–L 1 2 3 6 5 4 3 1 2 1 4 D12 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR RH 2 D11 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR LH 1 BB1 7 IQ1 3 W–B W–B W–B W–B A B M W–B W–B M W–B UNLOCK LOCK D14 DOOR LOCK MOTOR, DOOR KEY LOCK AND UNLOCK SW AND DOOR UNLOCK DETECTION SW FRONT RH 4 W–L R 2 IN1 W–L G 12 IN1 G IF1 L–B 1 11 IN1 M B A A B J18 A , J19 B 1 BA1 W–B JUNCTION CONNECTOR A A A J17 JUNCTION CONNECTOR A W–B IG 2001 PRIUS (EWD414U) BI FROM POWER SOURCE SYSTEM (SEE PAGE 50) 10A HORN B8 A , B9 B 1 5 BODY ECU HORN RELAY L1 UL1 14 B SH HCTY 20 A 15 B IND 13 A HR 13 B 2 3 10 A A 2 IQ1 A J7 JUNCTION CONNECTOR W–B 3 W–B 8 C R3 B , R4 C RADIO AND PLAYER A IE J1 JUNCTION CONNECTOR BR W–B 7 B IF 2001 PRIUS (EWD414U) D D J20 JUNCTION CONNECTOR R–W BR D10 DOOR LOCK CONTROL SW FRONT RH 6 4 W–B LOCK UNLOCK 2 C7 CENTER CLUSTER SW 5 1 E2 ENGINE HOOD COURTESY SW R–B 6 1 T1 THEFT DETERRENT HORN 6 IN1 G–B B–W 1 IN1 8 IA2 LG–B A 4 ID2 B–R IE1 B–R 10 R–B G–B IE1 B–R A 9 J27 JUNCTION CONNECTOR B–R B–R B–W R–W LG–B 2 1J THEFT DETERRENT SERVICE HINTS D13 DOOR KEY LOCK AND UNLOCK SW AND DOOR UNLOCK DETECTION SW FRONT LH 6–3 : Closed with door lock cylinder unlocked with key 5–3 : Closed with door lock cylinder locked with key D14 DOOR KEY LOCK AND UNLOCK SW AND DOOR UNLOCK DETECTION SW FRONT RH 1–4 : Closed with door lock cylinder unlocked with key 2–4 : Closed with door lock cylinder locked with key E2 ENGINE HOOD COURTESY SW 2–1 : Open with engine hood open U1 UNLOCK WARNING SW 2–1 : Closed with ignition key in cylinder L4 LUGGAGE COMPARTMENT DOOR KEY UNLOCK SW 2–1 : Closed with luggage compartment door lock cylinder unlock B8 (A), B9 (B) BODY ECU (A)17–GROUND : Continuity with front RH door unlocked (B) 1–GROUND : Always continuity (A) 5–GROUND : Continuity with luggage compartment door unlocked (A)13–GROUND : Continuity with engine hood closed (A) 5–GROUND : Continuity with luggage compartment door open (A)12–GROUND : Continuity with front RH door open (B) 9–GROUND : Always approx. 12 volts 8–GROUND : Always approx. 12 volts 15–GROUND : Approx. 12 volts with the ignition SW at ON position 6–GROUND : Continuity with rear LH, RH door open 3–GROUND : Continuity with front LH door open : PARTS LOCATION Code B8 B9 See Page Code See Page Code See Page A 36 E2 34 J22 A 37 B 36 J1 37 J23 B 37 C7 36 J7 37 J24 A 37 D4 36 J11 37 J25 B 37 D6 38 J12 A 37 J26 37 D7 38 J13 B 37 J27 37 D8 38 J14 A 37 J33 38 J15 B 38 D9 38 37 L4 D10 38 J16 37 P9 D11 38 J17 37 R3 B 37 D12 38 J18 A 37 R4 C 37 D13 38 J19 B 37 T1 35 D14 38 37 U1 37 J20 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1J 2C 2D 2G See Page Junction Block and Wire Harness (Connector Location) 27 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Panel LH) 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) 31 Cowl Wire and Instrument Panel J/B ((Cowl Side Panel LH)) 31 Floor Wire and Instrument Panel J/B (Cowl Side Panel LH) 2I 2J 2K 2L 2001 PRIUS (EWD414U) 39 : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IA2 42 Engine Room Main Wire and Cowl Wire (Cowl Side Panel LH) IB1 42 Floor Wire and Cowl Wire (Cowl Side Panel LH) IC1 42 Front Door LH Wire and Cowl Wire (Left Kick Panel) ID2 42 Instrument Panel Wire and Cowl Wire (Left Kick Panel) IE1 42 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IF1 42 Instrument Panel Wire and Floor Wire (Left Kick Panel) IG1 42 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) IN1 44 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IQ1 44 Front Door RH Wire and Cowl Wire (Right Kick Panel) BA1 46 Rear Door No.2 Wire and Floor Wire (Center Pillar LH) BB1 46 Rear Door No.1 Wire and Cowl Wire (Center Pillar RH) : GROUND POINTS Code ID IE See Page Ground Points Location 42 Cowl Side Panel LH IF 42 Left Kick Panel IG 42 Cowl Side Panel RH BI 46 Left Side of Rear Pillar BJ 46 Right Side of Rear Pillar 2001 PRIUS (EWD414U) RADIO AND PLAYER FROM POWER SOURCE SYSTEM (SEE PAGE 50) BR 15A DOME 10A ACC N2 NAVIGATION ECU 17 GND 2 2D AUO+ IJ2 9 L–Y GR–R 4 B 3 B BU+B 6 B FL+ FL– R2 A , R3 B , R4 C 2 F14 FRONT DOOR SPEAKER LH 1 2 F15 FRONT DOOR SPEAKER RH RR+ 8 IF1 1 2 R8 REAR SPEAKER LH 2001 PRIUS (EWD414U) W 3 A R Y IF1 RR– 1 A 5 IF1 6 IF1 W 7 Y L 4 IN1 RL– 6 A R RL+ 2 A B LG 3 IN1 L (* 2) V (* 2) 4 IG1 1 FR– 5 B LG (* 2) V (* 2) P P 3 IG1 FR+ 1 B B FL– 1 (*1) R 2 F14 FRONT DOOR SPEAKER LH RADIO AND PLAYER 6 B V P (* 1) V 2 B ACC+B FL+ (*1) GR–R B GR–R IJ2 4 IG1 1 P C B B (* 1) J24 JUNCTION CONNECTOR C A J26 JUNCTION CONNECTOR C A JUNCTION CONNECTOR B J27 A , J28 B 3 IG1 B 2 B 7 IJ2 L–Y 8 B R G G L–Y 4 2D IJ2 IJ1 2 R9 REAR SPEAKER RH (*1) 4 (*1) IJ1 11 (* 1) V 6 1 AUO– 2 10 (* 1) AUI– 1 GR–R L–Y GR–R 2 2G AUI+ (* 1) ACC 18 P L–Y +B 9 (* 1) 7 1J * 1 : W/ NAVIGATION SYSTEM * 2 : W/O NAVIGATION SYSTEM BR M5 MULTI DISPLAY C R +B 2 L–R P–B 9 GR EJCT 1 BR GR P–B L–R J26 JUNCTION CONNECTOR G 10 C 9 C 8 C 12 C 11 C 5 C GND ACC+B EJECT BU+B R2 A , R3 B , R4 C RADIO AND PLAYER GND 7 B BR 21 IJ1 BR TX– BR TX+ BR F G ACC 4 R C F GND BR F TX+ 7 R C TX– 8 G 10 G TX– 3 R TX+ C7 CENTER CLUSTER SW IF 2001 PRIUS (EWD414U) RADIO AND PLAYER SERVICE HINTS R3 (B) RADIO AND PLAYER (B)4–GROUND : Always approx. 12 volts (B)3–GROUND : Approx. 12 volts with the ignition SW at ON or ACC position (B)7–GROUND : Always continuity N2 NAVIGATION ECU 9–GROUND : Always approx. 12 volts 18–GROUND : Approx. 12 volts with the ignition SW at ON or ACC position 17–GROUND : Always continuity : PARTS LOCATION Code See Page Code See Page Code 36 J27 F14 38 J28 F15 38 M5 37 R8 39 J24 37 N2 39 R9 39 J26 37 R2 A 37 R3 B 37 R4 See Page C7 A B 37 C 37 37 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1J 27 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 2D 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Panel LH) 2G 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IF1 42 Instrument Panel Wire and Floor Wire (Left Kick Panel) IG1 42 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 44 Floor No.3 No 3 Wire and Instrument Panel Wire (Under the Instrument Panel Center) 44 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IJ1 IJ2 IN1 : GROUND POINTS Code IF See Page 42 Ground Points Location Left Kick Panel 2001 PRIUS (EWD414U) MEMO 2001 PRIUS (EWD414U) NAVIGATION SYSTEM FROM POWER SOURCE SYSTEM (SEE PAGE 50) G1 GATEWAY ECU 10A ACC GR–R L–Y R VG R 6 B 2 B BR 7 IJ1 22 IJ1 W (SHIELDED) G (SHIELDED) 16 IJ1 10 B W 5 B (SHIELDED) P–B G J12 A , J13 B R IJ1 E 1 P2 PARKING BRAKE SW 6 R GR–R E (SHIELDED) R–Y L–Y B 13 TC L–Y GR–R IJ1 9 A 18 A +B JUNCTION CONNECTOR E A GR–R J26 JUNCTION CONNECTOR 4 TX1– 10 B I5 E B L–Y IJ1 TX1+ 5 B D B 1 TC 14 A J26 JUNCTION CONNECTOR J27 A , J28 B C B PKB 13 A TX3+ 7 ID1 JUNCTION CONNECTOR C B GR–R J24 A , J25 B C A 4 A P–B J21 JUNCTION CONNECTOR D B–Y JUNCTION CONNECTOR C B +B1 1 C B–Y GR–R L–Y B A ACC 4 C B–Y L–Y J14 JUNCTION CONNECTOR IG 2 C 2 2G B A 11 A TX3– D 4 2D 5 M5 A , M6 B , M7 C MULTI DISPLAY D 5 ID1 GTX+ G 2 2I GTX– 12 R–Y 2 2D B–Y 7 1J 5A ECU–IG R–Y 15A DOME D2 DATA LINK CONNECTOR 3 ACC TX1+ N2 A , N3 B NAVIGATION ECU 2001 PRIUS (EWD414U) TX1– 2 B R BR FROM POWER SOURCE SYSTEM (SEE PAGE 50) 6 C TX– TX+ 8 7 R M5 A , M6 B , M7 C MULTI DISPLAY G C7 CENTER CLUSTER SW 10A GAUGE 3 2C B VR SPD 1 B TX+ 5 A V–W 3 B TX– 3 A 10 A G SYNC 8 B R G 7 B C F R–L GND1 J27 A G A JUNCTION CONNECTOR F C C F R G G A V–W V–W (SHIELDED) Y G B R G A 10 9 J26 JUNCTION CONNECTOR R–L 1 3 IJ1 7 2B 15 IJ1 18 IJ1 19 IJ1 20 IJ1 R4 RADIO AND PLAYER 5 R–B 2 V–W (SHIELDED) L Y G 6 2A B B5 BACK–UP LIGHT RELAY TX– W–G IJ1 R J27 A D A G 8 B SYNC 3 B B 1 B 6 B VR 5 A VG GND BR R–B 14 A 21 IJ1 5 IJ1 14 A C10 A , C11 B COMBINATION METER 7 2A 6 2B BR BR N2 A , N3 B 1 B REV 17 A NAVIGATION ECU 13 A SPD L 7 B IF IH 2001 PRIUS (EWD414U) R–B JUNCTION CONNECTOR D A BR 17 TX+ 3 NAVIGATION SYSTEM SERVICE HINTS N2 (A) NAVIGATION ECU (A) 9–GROUND : Always approx. 12 volts (A)18–GROUND : Approx. 12 volts with the ignition SW at ON or ACC position (A)17–GROUND : Always continuity M7 (C) MULTI DISPLAY (C)2–GROUND : Approx. 12 volts with the ignition SW at ON position (C)4–GROUND : Approx. 12 volts with the ignition SW at ON or ACC position (C)6–GROUND : Always continuity : PARTS LOCATION Code See Page B5 Code 36 C7 See Page J14 36 J21 Code See Page 37 M6 B 37 37 M7 C 37 C10 A 36 J24 A 37 N2 A 39 C11 B 36 J25 B 37 N3 B 39 D2 36 37 P2 37 G1 37 J27 J26 A 37 R4 37 J12 A 37 J28 B 37 J13 B 37 M5 A 37 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1J See Page Junction Block and Wire Harness (Connector Location) 27 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Panel LH) 2G 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) 2I 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) 2A 2B 2C 2D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) ID1 42 Instrument Panel Wire and Cowl Wire (Left Kick Panel) IJ1 44 Floor No.3 Wire and Instrument Panel Wire (Under the Instrument Panel Center) : GROUND POINTS Code See Page Ground Points Location IF 42 Left Kick Panel IH 42 Right Kick Panel : SPLICE POINTS Code I5 See Page 44 Wire Harness with Splice Points Code Instrument Panel Wire 2001 PRIUS (EWD414U) See Page Wire Harness with Splice Points MEMO 2001 PRIUS (EWD414U) GATEWAY SYSTEM FROM POWER SOURCE SYSTEM (SEE PAGE 50) 5 2C C A F A 5A ECU–IG 2 2I B–Y 2 2D R–G 7. 5A ECU–B GR–R 10A ACC D J14 JUNCTION CONNECTOR D JUNCTION CONNECTOR C B GR–L B–Y J27 A , J28 B 14 H B 5 ID1 B–Y MPX1 MPX2 13 ACC BATT G1 GATEWAY ECU GR–L 8 B–Y D GR J21 JUNCTION CONNECTOR R–G GR–R D 9 E10 ENGINE CONTROL MODULE 2 11 IG 16 MPX– MPX+ MPD2 B8 BODY ECU 5 GND CG 14 MPD1 4 7 2 J21 JUNCTION CONNECTOR W–B R G E GR–B GTX+ W–B GTX– 12 GR–B 15 MPX+ MPX– 3 TX3– 4 GR W–B E 11 C11 COMBINATION METER D B TX3+ 11 J22 A , J23 B E A MP2+ W–B M5 MULTI DISPLAY MPX+ JUNCTION CONNECTOR 4 A J24 JUNCTION CONNECTOR A W–B A 8 2D 8 2K W–B W–B A J11 JUNCTION CONNECTOR ID 2001 PRIUS (EWD414U) GR–B A7 A/C AMPLIFIER SERVICE HINTS G1 GATEWAY ECU 8–GROUND : Always approx. 12 volts 2–GROUND : Approx. 12 volts with the ignition SW at ON position 9–GROUND : Approx. 12 volts with the ignition SW at ACC or ON position 7, 14–GROUND : Always continuity : PARTS LOCATION Code See Page Code See Page Code A7 36 J11 37 B8 36 J14 37 J27 C11 36 37 J28 E10 36 J22 A 37 G1 37 J23 B 37 J21 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 2C 2D 2I 2K See Page Junction Block and Wire Harness (Connector Location) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Panel LH) 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code ID1 See Page 42 Joining Wire Harness and Wire Harness (Connector Location) Instrument Panel Wire and Cowl Wire (Left Kick Panel) : GROUND POINTS Code ID See Page 42 Ground Points Location Cowl Side Panel LH 2001 PRIUS (EWD414U) See Page J24 M5 37 A 37 B 37 37 ELECTRIC TENSION REDUCER FROM POWER SOURCE SYSTEM (SEE PAGE 50) 5A ECU–IG B–Y 4 2C IJ1 B–Y 12 1 T6 TENSION REDUCER SOLENOID G 2 3 B20 TENSION REDUCER LH [BUCKLE SW LH] W–B 1 IJ1 W–B 11 D B J22 A , J23 B JUNCTION CONNECTOR W–B E A A J24 JUNCTION CONNECTOR W–B A 8 2D W–B 8 2K A J11 JUNCTION CONNECTOR ID 2001 PRIUS (EWD414U) SERVICE HINTS T6 TENSION REDUCER SOLENOID 1–GROUND : Approx. 12 volts with the ignition SW at ON position B20 TENSION REDUCER LH 1–2 : Closed with driver’s seat belt in use : PARTS LOCATION Code See Page Code See Page Code See Page B20 38 J22 A 37 J24 37 J11 37 J23 B 37 T6 39 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 2C 2D 2K See Page Junction Block and Wire Harness (Connector Location) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Panel LH) 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IJ1 See Page 44 Joining Wire Harness and Wire Harness (Connector Location) Floor No.3 Wire and Instrument Panel Wire (Under the Instrument Panel Center) : GROUND POINTS Code ID See Page 42 Ground Points Location Cowl Side Panel LH 2001 PRIUS (EWD414U) EMPS FROM POWER SOURCE SYSTEM (SEE PAGE 50) 1 GR–G 10A GAUGE 50A EMPS 7. 5A ECU–B 5A ECU–IG P–B 2 W E A E A P–B W J22 JUNCTION CONNECTOR GR–G B–R L 2 2I J26 JUNCTION CONNECTOR 6 2G R–G 3 B–Y 5 2A 14 13 7 D A J14 A , J15 B JUNCTION CONNECTOR E B TC SIL B–Y B–R R–G TS D2 DATA LINK CONNECTOR 3 22 3 EMPS ECU IG RLY 2 D 2 WL 7 D M1 M2 1 B 2 B 7 IA2 1 IM1 Y B 3 B 3 PIG 1 C GR Y B–Y 5 GR L E3 A , E4 B , E5 C , E6 D 5 D GR 11 3 1 EMPS RELAY B 14 L C10 COMBINATION METER 3 3 IP1 L 7 2A BR 2 M BR B–Y 1 IH 2001 PRIUS (EWD414U) D1 DC MOTOR 6 2B GR–G 3 ID1 GR–G P–B 2 ID1 P–B W 1 ID1 W E C B J16 JUNCTION CONNECTOR GR–G B P–B C W–L E 1 D 3 D 9 D TC TS E3 A , E4 B , E5 C , E6 D SIL TRQG WRR WRL 10 D W 4 D B 3 A B TRQ2 2 A G 23 15 1 3 4 VCC VT1 VT2 GND 5 IO1 RRO RLO W–B 2 (SHIELDED) W–B I7 S1 STEERING SHAFT TORQUE SENSOR B11 BRAKE ECU A B A B J18 A , J19 B JUNCTION CONNECTOR A A W–B (SHIELDED) W–B TRQ1 4 A R TRQV 1 A W PGND 2 C A W–B J17 JUNCTION CONNECTOR A IG 2001 PRIUS (EWD414U) (SHIELDED) EMPS ECU EMPS SYSTEM OUTLINE In this system, the controller determines the direction and the amount of the assistant force based on the signals from the vehicle speed sensor and the torque sensor that is built in the gear box. The controller then assists the operation of the steering wheel by controlling the DC motor installed in the steering gear box. SERVICE HINTS E5 (C), E6 (D) EMPS ECU (D) 5–GROUND : Approx. 12 volts with the ignition SW at ON position (C) 2–GROUND : Always continuity : PARTS LOCATION Code See Page B11 36 C10 D1 D2 Code See Page Code See Page E5 C 36 J18 36 E6 D 36 J19 34 J14 A 37 J22 37 36 J15 B 37 J26 37 S1 35 E3 A 36 J16 37 E4 B 36 J17 37 A 37 B 37 : RELAY BLOCKS Code 3 See Page 24 Relay Blocks (Relay Block Location) Engine Room R/B No.3 (Engine Compartment Right) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 2A See Page Junction Block and Wire Harness (Connector Location) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Panel LH) 2G 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) 2I 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) 2B : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IA2 42 Engine Room Main Wire and Cowl Wire (Cowl Side Panel LH) ID1 42 Instrument Panel Wire and Cowl Wire (Left Kick Panel) IM1 44 Engine Room Main Wire and Cowl Wire (Right Kick Panel) IO1 44 Engine Wire and Cowl Wire (Right Kick Panel) IP1 44 Instrument Panel Wire and Cowl Wire (Right Kick Panel) : GROUND POINTS Code See Page Ground Points Location IG 42 Cowl Side Panel RH IH 42 Right Kick Panel : SPLICE POINTS Code I7 See Page 44 Wire Harness with Splice Points Code Engine Wire 2001 PRIUS (EWD414U) See Page Wire Harness with Splice Points SRS NOTICE: When inspecting or repairing the SRS, perform the operation in accordance with the following precautionary instructions and the procedure and precautions in the Repair Manual for the applicable model year.
Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery.
Work must be started after 90 seconds from when the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery. (The SRS is equipped with a back–up power source so that if work is started within 90 seconds from disconnecting the negative (–) terminal cable of the battery, the SRS may be deployed.)
When the negative (–) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as they were before and adjust the clock. To avoid erasing the memory in each memory system, never use a back–up power supply from outside the vehicle.
Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs.
Do not expose the steering wheel pad, front passenger airbag assembly, side airbag assembly, seat belt pretensioner, airbag sensor assembly or side airbag sensor directly to hot air or flames.
Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, side airbag assembly, seat belt pretensioner, airbag sensor assembly and side airbag sensor assembly should be inspected.
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
Never disassemble and repair the steering wheel pad, front passenger airbag assembly, side airbag assembly, seat belt pretensioner, airbag sensor assembly or side airbag sensor assembly in order to reuse it.
If the steering wheel pad, front passenger airbag assembly, side airbag assembly, seat belt pretensioner, airbag sensor assembly or side airbag sensor assembly has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones.
Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting the system’s electrical circuits.
Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices.
After work on the SRS is completed, perform the SRS warning light check.
If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section of the Repair Manual. 2001 PRIUS (EWD414U) SRS FROM POWER SOURCE SYSTEM (SEE PAGE 50) ACC AM1 10A SRS ACC IG1 4 2E IG2 6 GR W–R 7 AM2 B–W ST2 I15 IGNITION SW 2 2C 5 2B 1 2G 2 2E H13 HYBRID VEHICLE CONTROL ECU S4 SIDE AIRBAG SENSOR LH S5 SIDE AIRBAG SENSOR RH ABFS 1 2 3 4 1 2 3 4 GR (* 1) LG (* 1) (* 1) L–Y P (* 1) (* 1) GR–L (* 1) 7 A LG–B P–L 23 B (* 1) L 6 B L–W GR 5 B (* 1) B–O W–R 3 9 1J IG2 ACC GSW2 10 A VUPL 12 A SSL+ 9 A SSL– 12 C ESL VUPR 9 C SSR+ 7 C SSR– 10 C ESR A17 A , A18 B , A19 C 2 1 PL+ PL– PR+ PR– 2 A 1 A 5 C 6 C Y 1 SFR+ 1 C Y–B Y–R 2 SFR– 2 C Y Y–G 1 SFL– 5 A Y–B Y–R SFL+ (* 1) 6 A Y–R 11 B (* 1) 10 B Y–G 13 B (* 1) 14 B Y–G P– (* 1) P+ Y D+ 2 1 2 1 B 2 1B AIRBAG SENSOR ASSEMBLY D– Y–B 15A AM2 1 C F12 C , F13 D FUSIBLE LINK BLOCK NO. 1 B–G 1 D 120A MAIN 1 F18 FUSIBLE LINK BLOCK NO. 2 SPIRAL CABLE A21 AIRBAG SQUIB (STEERING WHEEL PAD) A20 AIRBAG SQUIB (FRONT PASSENGER AIRBAG ASSEMBLY) 2 S6 SIDE AIRBAG SQUIB LH BATTERY 2001 PRIUS (EWD414U) 2 1 S7 SIDE AIRBAG SQUIB RH P14 PRETENSIONER LH P15 PRETENSIONER RH FROM POWER SOURCE SYSTEM (SEE PAGE 50) * 1 : W/ SIDE AIRBAGS D2 DATA LINK CONNECTOR 3 AB C10 A , C11 B 9 2A GR–R 4 2B 14 A J27 A , J28 B B L C B E C A L B–Y J22 A , J23 B E 5 B C B JUNCTION CONNECTOR J26 JUNCTION CONNECTOR W P–B 16 A A A 2 2D SRS WARNING LIGHT [COMB. METER] B 1 2E P–B W B–Y J26 JUNCTION CONNECTOR 19 B 12 B 3 B TC SIL LA A17 A , A18 B , A19 C B9 BODY ECU IJ1 L 8 2K 6 2B 1 BR W–B A A A B 10 W–B 2001 PRIUS (EWD414U) IJ1 A W–B A A 8 2D 7 2A W–B F2 FRONT AIRBAG SENSOR RH W–B E A F1 FRONT AIRBAG SENSOR LH 3 2E W–B D B W–B W–B 11 W–B 1 J24 A , J25 B 2 3 JUNCTION CONNECTOR 1 2 1 J22 A , J23 B 2 IJ1 P–L B20 BUCKLE SW LH IL1 JUNCTION CONNECTOR 4 9 W–B IL1 BR–W 3 B–W IL1 BR 2 W–R IL1 E1 27 B P–L G–O 2 1 E2 28 B 3 A B21 BUCKLE SW RH AND SEAT BELT WARNING OCCUPANT DETECTION SENSOR A 8 C W–B RBE+ 11 A G–O B–W LBE+ –SR 20 B J29 JUNCTION CONNECTOR 9 B G–O 26 B BR–W 15 B BR +SR W–R –SL W–B AIRBAG SENSOR ASSEMBLY +SL J11 JUNCTION CONNECTOR ID IH JUNCTION CONNECTOR 6 GR–R SIL 7 GR–R TC 13 10A ACC SRS SYSTEM OUTLINE The SRS is a driver and front passenger protection device which has a supplemental role to the seat belts. When the ignition SW is turned to ACC or ON, current from the SRS ACC fuse flows to TERMINAL (B) 6 of the airbag sensor assembly. Only when the ignition SW is on does the current flow TERMINAL (B) 5 of the airbag sensor assembly. If an accident occurs while driving, when the frontal impact exceeds a set level, current flows to TERMINALS (B) 14, (B) 10, (A) 2 and (C) 5 of the airbag sensor assembly to TERMINAL 1 of the airbag squibs and the pretensioners to TERMINAL 2 to TERMINALS (B) 13, (B) 11, (A) 1 and (C) 6 of the airbag sensor assembly to TERMINAL (B) 27, (B) 28 or BODY GROUND to GROUND, so that current flows to the front airbag squibs and the pretensioners and causes them to operate. When the side impact also exceeds a set level, current from the ignition SW (IG2) or SRS ACC fuse flows to TERMINALS (A) 5, (C) 2, (A) 2 and (C) 5 of the airbag sensor assembly to TERMINAL 1 of the side airbag squibs and the pretensioners to TERMINAL 2 to TERMINALS (A) 6, (C) 1, (A) 1 and (C) 6 of the airbag sensor assembly to TERMINAL (B) 27, (B) 28 or BODY GROUND to GROUND, causing side airbag squibs and the pretensioners to operate. The airbag stored inside the steering wheel pad is instantaneously expanded to soften the shock to the driver. The airbag stored inside the passenger’s instrument panel is instantaneously expanded to soften the shock to the front passenger. Side airbags are instantaneously expanded to soften the shock of side to the driver and front passenger (w/ side airbags). The pretensioners make sure of the seat belt restrainability. : PARTS LOCATION Code A17 See Page Code See Page F1 34 Code 36 A18 B 36 A19 C 36 F12 C 34 J27 A 37 A20 36 F13 D 34 J28 B 37 A21 36 F18 38 J29 37 B9 36 H13 37 P14 39 B20 38 I15 37 P15 39 B21 38 J11 37 S4 39 F2 J25 See Page A 34 B J26 37 37 C10 A 36 J22 A 37 S5 39 C11 B 36 J23 B 37 S6 39 36 J24 A 37 S7 39 D2 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1B See Page Junction Block and Wire Harness (Connector Location) 27 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl ( Side Panel LH)) 2G 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) 2K 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) 1J 2A 2B 2C 2D 2E : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IJ1 44 Floor No.3 Wire and Instrument Panel Wire (Under the Instrument Panel Center) IL1 44 Instrument Panel Wire and Engine Room Main Wire (Right Kick Panel) : GROUND POINTS Code See Page Ground Points Location ID 42 Cowl Side Panel LH IH 42 Right Kick Panel 2001 PRIUS (EWD414U) MEMO 2001 PRIUS (EWD414U) ABS FROM POWER SOURCE SYSTEM (SEE PAGE 50) 1 1 20A ABS NO. 3 IG2 6 2 ST2 4 1K B 2 2C 3 B–W W–L I15 IGNITION SW 2 B–W 6 1K W–R 40A ABS NO. 1 W–R 7 AM2 30A ABS NO. 2 1 2G R W–R L–O 14 IA2 2 1B 4 3 2 3 3 1 4 3 6 2 4 B 2 1 2 ABS SOL RELAY 3 2 HYDRO MTR NO. 1 RELAY 1 2 HYDRO MTR NO. 2 RELAY 2 15A AM2 Y–B Y–B L–O 9 1J Y–B 3 R 3 W–B 2 LG–R 2 G 1 C 2 Y–G G–W 2 3 B–L F12 C , F13 D FUSIBLE LINK BLOCK NO. 1 LG–R Y–G B–G 1 D 1 F18 FUSIBLE LINK BLOCK NO. 2 120A MAIN G G–W W–B BATTERY 2001 PRIUS (EWD414U) B1 A , B2 B , B3 C BRAKE ACTUATOR 9 C 5 C 10 C 2 B 12 C 3 B 4 C 11 C 3 C 6 C 2 C 1 C R 1 B R–W Y–B R–G R–Y R–L G–W G–B G–O B–O L LG 5 2B R–B B–W 1 A 2 A 21 A 7 A 8 A 9 A 4 A 3 A 5 A 6 D 1 D 8 D 12 2G R L–O B–W Y–B 7 B R1+ 3 D R2+ 1 C IG2 SFRH SFRR SFLH SFLR SRRH SRRR SMC1 SMC2 SS AST SLA+ SLA– B10 A , B11 B , B12 C , B13 D BRAKE ECU MR2 2 D GND1 GND2 31 A 6 A W–B MR1 29 A W–B SR 19 A MTT MT+ 27 A 28 A MT– PH 18 A 11 A PL 9 D Y–G Y GR Y–R LG–R W–L B–L 3 B 3 A 6 A 1 A 5 B Y–G H5 A , H6 B 1 B 4 A 4 B W–B 5 A W–B 2 B W–B 2 A W–B W–B W–B HYDRAULIC BOOSTER G G–W W–B A J1 JUNCTION CONNECTOR A W–B A A A A J7 JUNCTION CONNECTOR IE 2001 PRIUS (EWD414U) W–B E5 W–B E5 W–B W–B E5 W–B ABS B1 A , B2 B , B3 C BRAKE ACTUATOR SLR– SG2 (SHIELDED) 15 C EREG R 24 C PREG 3 A W 25 C VREG 7 A B 16 C SG1 (SHIELDED) (SHIELDED) 12 A E2 11 A R 23 A PMC 4 A W 22 A VCM 8 A B 10 A (SHIELDED) (SHIELDED) 12 A R 1 A W 7 D 5 A B V 16 D SLR+ 9 A (SHIELDED) 7 C P 8 C 9 C 28 C 27 C 18 C VFR PFR EFR SG3 B10 A , B11 B , B12 C , B13 D BRAKE ECU GND4 FL+ 17 B FL– 15 A FSS 24 A FR+ FR– 14 A 13 A RL+ RL– 19 B 20 B L IB1 2 A4 ABS SPEED SENSOR FRONT LH 2 1 A5 ABS SPEED SENSOR FRONT RH A J11 JUNCTION CONNECTOR ID 2001 PRIUS (EWD414U) L IB1 1 2 A23 ABS SPEED SENSOR REAR LH (SHIELDED) 1 P 1 W–B W–B 1 2 W–B 2 B4 BRAKE FLUID LEVEL WARNING SW 5 IB1 P (SHIELDED) (SHIELDED) G I1 R (SHIELDED) W–B W–B LG–R BR 16 A L GND3 8 B P LBL 7 C FROM POWER SOURCE SYSTEM (SEE PAGE 50) B1 A , B2 B , B3 C BRAKE ACTUATOR 1 5A ECU–IG 10A ABS NO. 4 10 A 6 A 2 A 2 2 2I B–Y 3 B–Y 2 BUZZER JUNCTION CONNECTOR E B L (SHIELDED) E B 1 G R W B (SHIELDED) J14 A , J15 B B14 BRAKE WARNING BUZZER D A B–Y B–Y IA2 G 13 5 D VRR 13 D 20 D PRR 19 D ERR 6 B 22 D SG4 20 C IG1 +BS BZ B10 A , B11 B , B12 C , B13 D BRAKE ECU RRO W HVO– RLO 15 B B 17 HVO+ (SHIELDED) 18 23 B W–B HVI– 4 10 E6 EMPS ECU 30 HVI+ (SHIELDED) 20 R–Y 1 HVO– 22 B I3 18 IA2 W–B (SHIELDED) Y BR I3 (SHIELDED) I3 HVO+ 14 B R R–Y BR–B HVI– 16 B G HVI+ 24 B (SHIELDED) PKB 13 C V RR– 12 B LG RR+ 11 B H15 HYBRID VEHICLE CONTROL ECU 2 A A24 ABS SPEED SENSOR REAR RH J10 JUNCTION CONNECTOR A E J12 JUNCTION CONNECTOR A A B E J18 A , J19 B R–Y 1 P2 PARKING BRAKE SW JUNCTION CONNECTOR W–B A A W–B RSS 21 B A A J17 JUNCTION CONNECTOR J11 JUNCTION CONNECTOR ID 2001 PRIUS (EWD414U) IG ABS FROM POWER SOURCE SYSTEM (SEE PAGE 50) 15A STOP 10A GAUGE 5 2A GR–L L R–B 9 2K 14 S3 STOP LIGHT SW MPX1 MPX2 13 GR 2 2K J14 A 4 JUNCTION CONNECTOR 16 A MPX– B–W V–R V–R G–W R–Y E A B–W PKB MPX+ B8 A E A BODY ECU G–W R–Y 1 E10 ENGINE CONTROL MODULE 2 15 A 18 B 2 B 1 IP1 2 IP1 SP1 GR–B WA L BRL L STP L 5 B 1 B 9 A 10 A 22 A 2 B B10 A , B11 B , B12 C , B13 D BRAKE ECU D/G TS 10 B 4 B P–B W–L GR–G ABS 3 B C E B C E B BRAKE TC 1 ID1 14 A 3 B C10 A , C11 B COMBINATION METER 13 7 TC SIL D2 DATA LINK CONNECTOR 3 GR–L GR 11 MPX+ MP2+ G1 GATEWAY ECU 6 2B A7 A/C AMPLIFIER GR–G 7 2A BR W A P–B E A J22 JUNCTION CONNECTOR J26 JUNCTION CONNECTOR E 3 ID1 W P–B L W 2 ID1 GR–G P–B J16 JUNCTION CONNECTOR 4 GR–B IH 2001 PRIUS (EWD414U) MPD2 MPD1 4 14 TS 11 SYSTEM OUTLINE 1. INPUT SIGNALS (1) Speed sensor signal The speed of the wheels is detected and input to TERMINALS FL+, FR+, RL+ and RR+ of the brake ECU. (2) Stop light SW signal A signal is input to TERMINAL STP of the brake ECU when the brake pedal is depressed. 2. ABS SYSTEM OPERATION During sudden braking the brake ECU has signals input from each sensor, which controls the current to the solenoid inside the actuator and lets the hydraulic pressure acting on each wheel cylinder escape to the reservoir. The pump inside the actuator is also operating at this time and it returns the brake fluid from the reservoir to the master cylinder, thus preventing locking of the vehicle wheels. If the brake ECU judges that the hydraulic pressure acting on the wheel cylinder is insufficient, the current on the solenoid is controlled and the hydraulic pressure is increased. Holding of the hydraulic pressure is also controlled by the brake ECU, by the same method as above. Pressure reduction, holding and increase are repeated to maintain vehicle stability and to improve steerability during sudden braking. SERVICE HINTS A4, A5 ABS SPEED SENSOR FRONT LH, RH 2–1 : 1.4–1.8 kΩ (20°C, 68°F) A23, A24 ABS SPEED SENSOR REAR LH, RH 2–1 : 1.04–1.3 kΩ (20°C, 68°F) B10 (A), B11 (B), B12 (C), B13 (D) BRAKE ECU (B) 6, (C) 1–GROUND : Approx. 12 volts with the ignition SW at ON position (D) 22–GROUND : Always approx. 12 volts (A) 6, (A)31–GROUND : Always continuity : PARTS LOCATION Code See Page Code See Page Code See Page A4 34 C10 A 36 J10 37 A5 34 C11 B 36 J11 37 A7 36 D2 36 J12 A23 38 E6 36 J14 A 37 A24 38 E10 36 J15 B 37 37 B1 A 34 F12 C 34 J16 37 B2 B 34 F13 D 34 J17 37 C 34 F18 38 J18 A 37 34 G1 37 J19 B 37 B3 B4 B8 A 36 H5 A 34 J22 37 B10 A 36 H6 B 34 J26 37 B11 B 36 H15 38 P2 37 B12 C 36 I15 37 S3 37 B13 D 36 J1 37 36 J7 37 B14 : RELAY BLOCKS Code See Page Relay Blocks (Relay Block Location) 2 23 Engine Room R/B No.2 (Right Side of Reserve Tank) 3 24 Engine Room R/B No.3 (Engine Compartment Right) 2001 PRIUS (EWD414U) ABS ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1B 1J 27 Engine g Room Main Wire and Engine g Room J/B (Engine ( g Compartment Left)) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl ( Side Panel LH)) 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) 1K 2A 2B 2C 2G 2I 2K : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IA2 42 Engine Room Main Wire and Cowl Wire (Cowl Side Panel LH) IB1 42 Floor Wire and Cowl Wire (Cowl Side Panel LH) ID1 42 Instrument Panel Wire and Cowl Wire (Left Kick Panel) IP1 44 Instrument Panel Wire and Cowl Wire (Right Kick Panel) : GROUND POINTS Code ID See Page Ground Points Location 42 Cowl Side Panel LH IG 42 Cowl Side Panel RH IH 42 Right Kick Panel IE : SPLICE POINTS Code See Page E5 40 I1 44 Wire Harness with Splice Points Engine Room Main Wire Code I3 2001 PRIUS (EWD414U) See Page 44 Wire Harness with Splice Points Cowl Wire MEMO 2001 PRIUS (EWD414U) REAR WINDOW DEFOGGER FROM POWER SOURCE SYSTEM (SEE PAGE 50) 1 40A DEF 10A GAUGE 2 5 1 DEF RELAY 3 4 2M 2 13 DFG MPX+ B8 A BODY ECU GR–B B 15 A 2 MPX+ C11 COMBINATION METER MPX– GR 3 1 11 REAR WINDOW DEFOGGER MPX REAR WINDOW DEFOGGER SW PSG SW RDEF A7 A/C AMPLIFIER N4 NOISE FILTER (REAR WINDOW DEFOGGER) 2001 PRIUS (EWD414U) SERVICE HINTS DEF RELAY 5–3 : Closed with the ignition SW on and the rear window defogger SW on : PARTS LOCATION Code See Page A7 B8 A Code See Page 36 C11 36 36 N4 39 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 2M See Page 31 Junction Block and Wire Harness (Connector Location) Floor Wire and Instrument Panel J/B (Cowl Side Panel LH) 2001 PRIUS (EWD414U) Code See Page COMBINATION METER FROM POWER SOURCE SYSTEM (SEE PAGE 50) B8 A , B9 B BODY ECU MPX– 16 B 9 2J BR–R 8 2J 5 1 6 BR–R 6 2J MPX+ 15 A GR–B FU– 19 GR FU+ 11 Y–B L–Y FUA 20 Y–B 7 1J R–G 5 2A B 9 B Y 5 2C 15A DOME Y 10A GAUGE R–G 7. 5A ECU–B L–R L–Y JUNCTION CONNECTOR SENSOR F A 4 2A MPX2 MPX1 14 4 L GR–L L–Y L–W 8 R–G 13 4 IP1 E10 ENGINE CONTROL MODULE 2 2G J27 A L F A F16 FUEL SENDER FUEL SENDER 5 IP1 L L 20 A 12 A 6 B 1 B 9 A 11 A LG–R W–G L L GR–L C10 A , C11 B 22 A 21 A COMBINATION METER 1 BR H8 ODO/TRIP SW [HAZARD WARNING SW] IH 2001 PRIUS (EWD414U) FROM EMPS ECU 6 2B TC FROM BRAKE ECU ODO FROM BACK–UP LIGHT RELAY 5 E 7 B TO LIGHT CONTROL RHEOSTAT 3 7 2A 1 A W–L L 3 A L 2 A L 14 A L VFD 2 B 11 FROM HYBRID VEHICLE CONTROL ECU V–W G B FROM ENGINE CONTROL MODULE G B MPD2 J27 A , J28 B JUNCTION CONNECTOR G A 4 7 2B G A G A V–W 4 V–W MPD1 GR–B A7 A/C AMPLIFIER G1 GATEWAY ECU GR–L V–W FROM MULTI DISPLAY V–W FROM NAVIGATION ECU MP2+ MPX+ 6 2A L GR–L GR 11 3 B 13 A C10 A , C11 B BUZZER 2001 PRIUS (EWD414U) CHARGE OIL SEAT BELT (FRONT PASSENGER’ S SEAT) SEAT BELT (DRIVER’ S SEAT) BRAKE HEAD DOOR COMBINATION METER 2001 PRIUS (EWD414U) TO AIRBAG SENSOR ASSEMBLY TO BRAKE ECU TO ENGINE CONTROL MODULE 4 B 10 A 16 A L B–Y C10 A , C11 B L GR–R FROM HEADLIGHTS (* 1) FROM DAYTIME RUNNING LIGHT RELAY (* 2) FROM TURN SIGNAL FLASHER RELAY B HIGH BEAM COMBINATION METER L GR–R TURN R GR–R L C B GR–R JUNCTION CONNECTOR J26 JUNCTION CONNECTOR J27 A , J28 B TURN L SRS ABS MALFUNCTION INDICATOR LAMP B A G–R OUTPUT CONTROL WATER TEMP. (HIGH) WATER TEMP. (LOW) CRUISE COMBINATION METER FROM POWER SOURCE SYSTEM (SEE PAGE 50) * 1 : W/O DAYTIME RUNNING LIGHT * 2 : W/ DAYTIME RUNNING LIGHT 10A ACC 2 2D B 5 B 19 A 18 A 17 A SERVICE HINTS C10 (A), C11 (B) COMBINATION METER (A)22–GROUND : Approx. 12 volts with the ignition SW at ON position (B) 5–GROUND : Approx. 12 volts with the ignition SW at ON or ACC position (A)21–GROUND : Always approx. 12 volts (A)14–GROUND : Always continuity : PARTS LOCATION Code See Page A7 36 Code C11 See Page B Code See Page 36 H8 37 J26 37 B8 A 36 E10 36 B9 B 36 F16 38 J27 A 37 C10 A 36 G1 37 J28 B 37 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1J See Page Junction Block and Wire Harness (Connector Location) 27 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Panel LH) 2G 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) 2J 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) 2A 2B 2C 2D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IP1 See Page 44 Joining Wire Harness and Wire Harness (Connector Location) Instrument Panel Wire and Cowl Wire (Right Kick Panel) : GROUND POINTS Code IH See Page 42 Ground Points Location Right Kick Panel 2001 PRIUS (EWD414U) RADIATOR FAN AND CONDENSER FAN FROM POWER SOURCE SYSTEM (SEE PAGE 50) 1 30A RDI 30A CDS FAN 5A ECU–IG 2 7 2G 1 W–G 1 M 2 5 1K B–Y 2 12 1J 4 1J B–Y 2 1K 7 IE1 E5 RF A8 A/C AMPLIFIER 2 V–Y 1 W–B E A J27 A , J28 B A3 A/C SINGLE PRESSURE SW A B JUNCTION CONNECTOR V–Y 3 11 IE1 V–Y W–B W–B 10 1J 6 IE1 2 W4 WATER TEMP. SW A W–B J7 JUNCTION CONNECTOR A A W–B M FAN 5 1J A1 A/C CONDENSER FAN MOTOR G–W 4 R1 RADIATOR FAN MOTOR 3 R–W 2 FAN NO. 3 RELAY 2 L–W 11 1A LG L–W 3 1K 1 FAN NO. 2 RELAY 5 W–B 2 7 1K 5 4 FAN NO. 1 RELAY 3 1 V–Y 3 R–W 1 E7 ENGINE CONTROL MODULE 5 A 1 W–B A J1 JUNCTION CONNECTOR IE 2001 PRIUS (EWD414U) SYSTEM OUTLINE The radiator fan motor and A/C condenser fan motor operates according to the water temp. SW (Inverter), A/C single pressure SW, and the A/C system condition. The FAN NO.1 relay, FAN NO.2 relay, FAN NO.3 relay are turned on/off, to operate the fan motors at low speed (In series), or high speed (In parallel). 1. LOW SPEED OPERATION When the water temp. SW (Inverter) is on, the radiator fan motor and A/C condenser fan motor operates at low speed. 2. HIGH SPEED OPERATION When the water temp. SW (Inverter) is on, if the A/C system is operating A/C single pressure SW is on, the radiator fan motor and A/C condenser fan motor operates at high speed. SERVICE HINTS A3 A/C SINGLE PRESSURE SW 3–2 : Close above approx. 15.2 kgf/cm2 (220 psi, 1520 kpa) Open below approx. 12.3 kgf/cm2 (178 psi, 1230 kpa) : PARTS LOCATION Code See Page Code See Page A1 34 J1 A3 34 A8 36 J27 A 37 E7 36 J28 B 37 J7 Code See Page 37 R1 35 37 W4 35 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1A 1J 1K 2G See Page Junction Block and Wire Harness (Connector Location) 27 Engine Wire and Engine Room J/B (Engine Compartment Left) 27 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IE1 See Page 42 Joining Wire Harness and Wire Harness (Connector Location) Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) : GROUND POINTS Code IE See Page 42 Ground Points Location Cowl Side Panel LH : SPLICE POINTS Code E5 See Page 40 Wire Harness with Splice Points Code Engine Room Main Wire 2001 PRIUS (EWD414U) See Page Wire Harness with Splice Points AIR CONDITIONING FROM POWER SOURCE SYSTEM (SEE PAGE 50) 1 50A HTR 2 5 5 1 HTR RELAY 13 1J 5 1A 2 3 1F 4 1F 3 1K W–B 8 1K B–L 3 L–O 3 B–R 2 CLR MG RELAY R 4 LG–R 1 J2 A , A B LG–R JUNCTION CONNECTOR A A B–R A A J3 B 8 IE1 L–O LG–R B–L B 1 J6 JUNCTION CONNECTOR B–R M B6 BLOWER MOTOR B 13 IE1 R R B V R 3 L–Y R GND 3 3 4 1 3 A/C W/P RELAY 2 1 5 3 2 W2 WATER PUMP MOTOR (A/C) M 3 L–Y W–B W–B B7 BLOWER MOTOR LINEAR CONTROLLER 4 E5 1 L W–B SI A3 A/C DUAL PRESSURE SW +B W–B 2 VM W–B 1 V B–W 2 L–R W–B L–R J1 JUNCTION CONNECTOR A A IE 2001 PRIUS (EWD414U) A W–B A A A J7 JUNCTION CONNECTOR W–B FROM POWER SOURCE SYSTEM (SEE PAGE 50) 3 2D 5 2C R–G 7. 5A ECU–B R 10A HTR W L–O 1 A12 A/C THERMISTOR A B FROM FAN NO. 2 RELAY F A W A10 A/C ROOM TEMP. SENSOR F A FROM CONVERTER C A J27 A J22 A , J23 B C A JUNCTION CONNECTOR JUNCTION CONNECTOR R L–O 2 2 1 R–G Y R–W W W W W R R B–L LG–R LG–R 10 B 1 A 8 A 10 A 1 B 4 C 3 C 1 C 2 C IG +B MGC RF IDH V TR SGTR TE SGTE A7 A , A8 B , A9 C A/C AMPLIFIER SGLOCK 4 IE1 5 W–L 4 IK1 A B BR–W 1 4 2 A B W–B 8 2D 2 8 2K W–B A2 A/C MAGNETIC CLUTCH AND LOCK SENSOR W4 WATER TEMP. SW L–R W–B A A 11 IE1 V–Y W–L IK1 B–L L–Y 5 E A IE1 BR–W IE1 L–R L–Y V 20 GND 7 A W–B BR–W W–L L–R L–Y 15 IE1 V V A 21 IE1 CF 2 B 18 B J24 A , J25 B LOCK 9 B JUNCTION CONNECTOR W–B WP 3 B V–Y PSW 11 B J27 A , J28 B BLW 3 A JUNCTION CONNECTOR V–Y A J6 JUNCTION CONNECTOR 1 A J11 JUNCTION CONNECTOR ID 2001 PRIUS (EWD414U) AIR CONDITIONING B8 A BODY ECU HRLY 18 MPX+ MPX– 15 A 16 A 4 MEO2 3 D 13 D 23 C MPX2 ACT TAM E2 22 D 18 B 2 IK1 E 8 B , E 9 C , E10 D MPD1 MPX1 ENGINE CONTROL MODULE W–G 14 D MPD2 2 1 LG P–G 11 A 4 A 4 B 5 B MP2+ NE ACT A7 A , A8 B , A9 C A/C AMPLIFIER AIR 2 1 2 3 4 5 A11 A/C SOLAR SENSOR 21 C W AIF 22 C W TPI 19 C W S5TPI 18 C W SGTPI 20 C W TS 5 C W S5TS 6 C W MPX+ BR–W GR–B BR 3 11 G1 GATEWAY ECU MPX– C11 COMBINATION METER 2 MPX+ A6 AMBIENT TEMP. SENSOR W–G GR GR–B 5 IA2 GR–L GR L–O 6 2F 1 W M A14 AIR INLET CONTROL SERVO MOTOR 2001 PRIUS (EWD414U) TSET MSET PIG5 PSG SW A/C SW F/R SW RDEF SW FULL A/C PIG LED A/C LED F/R LED RDEF LED FULL A/C A7 A , A8 B , A9 C A/C AMPLIFIER II1 II1 4 II1 2 II1 W W W W 3 1 II1 Y–B 5 AOD 11 C R II1 AOF 10 C GR–L 10 W W II1 TPM 8 C BR–W 9 9 C W II1 SGTPM BR–R 7 S5TPM 7 C L II1 AMH 13 C Y–R 8 AMC 14 C BR–Y II1 W W 6 TP 16 C W SGTP 15 C W S5TP 17 C W–R BSET 1 2 3 4 5 1 2 3 4 5 M A15 AIR MIX CONTROL SERVO MOTOR M A16 AIR VENT MODE CONTROL SERVO MOTOR 2001 PRIUS (EWD414U) AIR CONDITIONING FROM POWER SOURCE SYSTEM (SEE PAGE 50) 1 1 10A GAUGE 1 50A HTR3 30A HTR2 2 2 3 2 3 B–R G–W 3 G R–L 8 2G R–L 3 1 R–L 3 3 3 2 3 1 3 3 HTR1 RELAY 5 3 2 3 5 3 3 P–B P G–R L–Y P–B 18 IE1 1 L–R P 3 HTR2 RELAY 5 3 3 3 HTR3 RELAY 2 30A HTR1 13 B 1 A HTR2 3 B 1 B P3 A , P4 B A7 A , A8 B , A9 C PTC HEATER A/C AMPLIFIER 2 A 4 B 2 B HTRO A A J1 JUNCTION CONNECTOR IE 2001 PRIUS (EWD414U) 5 IA1 W–B A IA1 W–B W–B 1 W–B 16 IE1 W–B P–B W–B 6 B J11 JUNCTION CONNECTOR ID SERVICE HINTS A3 A/C DUAL PRESSURE SW 1–4 : Open with the refrigerant pressure at less than approx. 196 kpa (2.0 kgf/cm2, 28.4 psi), or more than approx. 3140 kpa (32 kgf/cm2, 455 psi), A7 (A), A8 (B), A9 (C) A/C AMPLIFIER (A) 8–GROUND : Always approx. 12 volts (A) 1–GROUND : Approx. 12 volts with the ignition SW at ON position (A)24–GROUND : Always continuity : PARTS LOCATION Code See Page Code See Page Code See Page A2 34 B6 36 J7 37 A3 34 B7 36 J11 37 A6 34 B8 36 J22 A 37 36 J23 B 37 B 36 J24 A 37 E9 C 36 J25 B 37 E10 D 36 J27 A 37 G1 37 J28 B 37 J1 37 P3 A 37 A 37 P4 B 37 B 37 W2 35 37 W4 35 A7 A 36 A8 B 36 E8 A9 C 36 A10 36 A11 36 A12 36 A14 36 J2 A15 36 J3 A16 36 A C11 J6 : RELAY BLOCKS Code 3 See Page 24 Relay Blocks (Relay Block Location) Engine Room R/B No.3 (Engine Compartment Right) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1A See Page Junction Block and Wire Harness (Connector Location) 27 Engine Wire and Engine Room J/B (Engine Compartment Left) 27 Engine g Room Main Wire and Engine g Room J/B (Engine ( g Compartment Left)) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Panel LH) 31 Engine Room Main Wire and Instrument Panel J/B (Cowl Side Panel LH) 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) 1F 1J 1K 2C 2D 2F 2G 2K : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IA1 See Page Joining Wire Harness and Wire Harness (Connector Location) 42 Engine Room Main Wire and Cowl Wire (Cowl Side Panel LH) IE1 42 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) II1 44 Instrument Panel Wire and A/C Sub Wire (Instrument Panel Brace LH) IK1 44 Engine Wire and Engine Room Main Wire (Right Kick Panel) IA2 : GROUND POINTS Code ID IE See Page 42 Ground Points Location Cowl Side Panel LH 2001 PRIUS (EWD414U) AIR CONDITIONING : SPLICE POINTS Code E5 See Page 40 Wire Harness with Splice Points Code Engine Room Main Wire 2001 PRIUS (EWD414U) See Page Wire Harness with Splice Points MEMO 2001 PRIUS (EWD414U) I GROUND POINT W–B W–B W–B FRONT SIDE MARKER LIGHT RH W–B FRONT TURN SIGNAL LIGHT RH W–B BRAKE FLUID LEVEL WARNING SW W–B W–B W–B W–B W–B HYDRAULIC BOOSTER ABS SOL RELAY 3 W–B INVERTER A A E1 W–B E1 W–B EC (GND1) BRAKE ECU J1 JUNCTION CONNECTOR E1 W–B 3 W–B A E1 W–B A A W–B A A W–B (GND2) PTC HEATER BLOWER MOTOR LINEAR CONTROLLER IE (*1) IGNITION COIL AND IGNITER NO. 2 W–B IGNITION COIL AND IGNITER NO. 3 W–B IGNITION COIL AND IGNITER NO. 4 W–B J8 A , J9 B JUNCTION CONNECTOR A A B A E3 BR E3 14 IO1 BR BR W–B E3 14 ID2 BR (E1) ENGINE CONTROL MODULE (SG) DATA LINK CONNECTOR 3 (E01) BR W–B W–B IGNITION COIL AND IGNITER NO. 1 W–B DRL RELAY W–B W–B W–B W–B WATER TEMP. SW W–B W–B RADIATOR FAN MOTOR W–B E5 W–B FRONT SIDE MARKER LIGHT LH FRONT TURN SIGNAL LIGHT LH W–B E1 W–B W–B FRONT WIPER MOTOR W–B E5 A W–B E1 ENGINE HOOD COURTESY SW W–B E5 W–B FRONT PARKING LIGHT RH J7 JUNCTION CONNECTOR E5 W–B W–B W–B E5 W–B FRONT PARKING LIGHT LH IG2 RELAY HTR RELAY E5 E5 W–B W–B 3 1K EFI RELAY E5 W–B WATER PUMP MOTOR (A/C) W–B E5 E5 W–B HYDRAULIC BOOSTER W–B E5 W–B (CUT–) A W–B (–S) A/C TRIPLE PRESSURE SW A W–B E5 W–B 2 IGCT RELAY FAN NO. 2 RELAY W–B WATER PUMP MOTOR (INVERTER) W–B W–B W–B (ME01) ENGINE CONTROL MODULE W–B (E03) EB EA BR (* 2) AIRBAG SENSOR ASSEMBLY (E1) COMBINATION METER (ES) W–B L 7 2A ENGINE CONTROL MODULE (E02) 21 IJ1 BR (* 2) BR 6 2B BR BR IH IF 2001 PRIUS (EWD414U) NAVIGATION ECU RADIO AND PLAYER MULTI DISPLAY HYBRID VEHICLE CONTROL ECU (EOM) KEY INTERLOCK SOLENOID (KLS–) W–B E E W–B W–B E E W–B W–B E J21 JUNCTION CONNECTOR LIGHT CONTROL RHEOSTAT (E) (CG) GATEWAY ECU *1 : W/ DAYTIME RUNNING LIGHT *2 : W/ NAVIGATION SYSTEM J22 A , J23 B JUNCTION CONNECTOR D E B A W–B HAZARD WARNING SW W–B W–B WIRELESS DOOR CONTROL RECEIVER E A D B E A W–B A B A A W–B A B A A W–B W–B A B A A W–B W–B A B A A W–B A B A A 11 IJ1 W–B W–B BUCKLE SW AND TENSION REDUCER LH PARK/NEUTRAL POSITION SW D B W–B (TL) W–B A/C AMPLIFIER UNLOCK WARNING SW (UN–) REMOTE CONTROL SW SHIFT LOCK ECU BUCKLE SW RH AND SEAT BELT WARNING OCCUPANT DETECTION SENSOR W–B 10 IJ1 W–B 2 IG1 W–B W–B (E2) (CG) DATA LINK CONNECTOR 3 DOOR LOCK MOTOR, DOOR KEY LOCK AND UNLOCK SW AND DOOR UNLOCK DETECTION SW FRONT LH W–B J24 A , J25 B AIRBAG SENSOR ASSEMBLY GATEWAY ECU CIGARETTE LIGHTER JUNCTION CONNECTOR A A (GND) W–B 8 2D W–B 3 2E W–B 8 2K (E) BODY ECU IG1 RELAY W–B W–B TRANSPONDER KEY COMPUTER POWER WINDOW MASTER SW (E) A 1 IC1 W–B W–B 5 IA1 W–B A W–B 1 IA1 W–B A A J11 JUNCTION CONNECTOR FUEL PUMP AND FUEL SENDER W–B A W–B 1 BB1 A W–B 1 IQ1 J17 JUNCTION CONNECTOR W–B DAYTIME RUNNING LIGHT RELAY W–B A W–B PTC HEATER (E) A W–B J10 JUNCTION CONNECTOR A W–B W–B A W–B EMPS ECU B3 W–B POWER WINDOW CONTROL SW REAR RH W–B DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR RH (*1) (GND3) W–B A W–B POWER WINDOW CONTROL SW FRONT RH BRAKE ECU (GND4) W–B A ID W–B A A IG 2001 PRIUS (EWD414U) W–B (EL) COMBINATION SW I GROUND POINT REAR COMBINATION LIGHT LH W–B C B B A W–B LICENSE PLATE LIGHT LH W–B C B B A W–B HIGH MOUNTED STOP LIGHT W–B C B B A REAR COMBINATION LIGHT RH W–B LICENSE PLATE LIGHT RH W–B 1 BA1 W–B W–B PERSONAL LIGHT B1 W–B POWER WINDOW CONTROL SW REAR LH W–B DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR LH BI W–B BK W–B W–B J32 A , J33 B JUNCTION CONNECTOR BATTERY MOTOR BLOWER CONTROLLER SYSTEM MAIN RELAY LUGGAGE COMPARTMENT DOOR UNLOCK SW W–B B B W–B B B W–B BATTERY ECU W–B (E) COMBINATION SW (E) TURN SIGNAL FLASHER RELAY W–B W–B BATTERY FAN RELAY B B J32 A , J33 B BJ COMBINATION SW C A JUNCTION CONNECTOR W–B A A A B W–B 7 IQ1 W–B W–B A A A B W–B 2 IQ1 W–B W–B A A A B W–B W–B A A A B W–B A A A B W–B W–B J18 A , J19 B W–B 8 BC1 JUNCTION CONNECTOR BL 2001 PRIUS (EWD414U) DOOR LOCK MOTOR, DOOR KEY LOCK AND UNLOCK SW AND DOOR UNLOCK DETECTION SW FRONT RH DOOR LOCK CONTROL SW FRONT RH (ECC) COMBINATION SW (GND1) HYBRID VEHICLE CONTROL ECU (GND2) : PARTS LOCATION Code See Page J1 Code 37 J7 See Page J17 Code See Page 37 J24 A 37 37 J18 A 37 J25 B 37 J8 A 37 J19 B 37 J32 A 38 J9 B 37 37 J33 B 38 J21 J10 37 J22 A 37 J11 37 J23 B 37 : RELAY BLOCKS Code See Page Relay Blocks (Relay Block Location) 2 23 Engine Room R/B No.2 (Right Side of Reserve Tank) 3 24 Engine Room R/B No.3 (Engine Compartment Right) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1K See Page Junction Block and Wire Harness (Connector Location) 27 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 30 Instrument Panel Wire and Instrument Panel J/B (Cowl Side Panel LH) 31 Cowl Wire and Instrument Panel J/B (Cowl Side Panel LH) 2A 2B 2D 2E 2K : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IA1 42 Engine Room Main Wire and Cowl Wire (Cowl Side Panel LH) IC1 42 Front Door LH Wire and Cowl Wire (Left Kick Panel) ID2 42 Instrument Panel Wire and Cowl Wire (Left Kick Panel) IG1 42 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) IJ1 44 Floor No.3 Wire and Instrument Panel Wire (Under the Instrument Panel Center) IO1 44 Engine Wire and Cowl Wire (Right Kick Panel) IQ1 44 Front Door RH Wire and Cowl Wire (Right Kick Panel) BA1 46 Rear Door No.2 Wire and Floor Wire (Center Pillar LH) BB1 46 Rear Door No.1 Wire and Cowl Wire (Center Pillar RH) BC1 46 Cowl Wire and Fuel Tank Wire (Near the Fuel Tank) : GROUND POINTS Code EA EB EC ID IE See Page Ground Points Location 40 Engine Block 40 Engine Compartment Left 42 Cowl Side Panel LH IF 42 Left Kick Panel IG 42 Cowl Side Panel RH IH 42 Right Kick Panel BI 46 Left Side of Rear Pillar BJ 46 Right Side of Rear Pillar BK 46 Back Panel Center BL 46 Near the Fuel Tank 2001 PRIUS (EWD414U) I GROUND POINT : SPLICE POINTS Code See Page Wire Harness with Splice Points Code See Page Wire Harness with Splice Points E1 40 Engine Room Main Wire B1 46 Rear Door No.2 Wire E3 40 Engine Wire B3 46 Rear Door No.1 Wire E5 40 Engine Room Main Wire 2001 PRIUS (EWD414U) MEMO 2001 PRIUS (EWD414U) J POWER SOURCE (Current Flow Chart) 2001 PRIUS (EWD414U) J 2001 PRIUS (EWD414U) J POWER SOURCE (Current Flow Chart) Fusible Link Block No.1 (See Page 22) Fuse 100A DC/DC System Page Illumination Key Reminder and Light Reminder Buzzer Light Auto Turn Off Taillight 92 114 104 88 TOYOTA Hybrid System 54 Fusible Link Block No.2 (See Page 23) Fuse 5A 120A DC/DC–S MAIN System Page TOYOTA Hybrid System 54 ABS Engine Control Headlight (w/o Daytime Running Light) Hybrid Vehicle Immobiliser System 172 68 84 78 Illumination Key Reminder and Light Reminder Buzzer Light Auto Turn Off SRS 92 114 104 167 Taillight TOYOTA Hybrid System 88 54 Engine Room R/B No.3 (See Page 24) Fuse System Page 7.5A DRL Headlight (w/ Daytime Running Light) 80 10A ABS NO.4 ABS 172 30A HTR1 Air Conditioning 188 30A HTR2 Air Conditioning 188 40A ABS NO.1 ABS 172 50A EMPS EMPS 164 50A HTR3 Air Conditioning 188 Engine Room J/B (See Page 26) Fuse System Page 10A BATT FAN TOYOTA Hybrid System 54 10A HEAD (LH) Headlight (w/o Daytime Running Light) 84 10A HEAD (RH) Headlight (w/o Daytime Running Light) 84 10A HEAD HI (LH) Headlight (w/ Daytime Running Light) 80 10A HEAD HI (RH) Headlight (w/ Daytime Running Light) 80 10A HEAD LO (LH) Headlight (w/ Daytime Running Light) 80 10A HEAD LO (RH) Headlight (w/ Daytime Running Light) 80 10A HORN Horn Theft Deterrent 124 146 10A TURN–HAZ Turn Signal and Hazard Warning Light 96 ∗ These are the page numbers of the first page on which the related system is shown. 2001 PRIUS (EWD414U) J Fuse 15A 15A AM2 DOME System Page ABS Engine Control Hybrid Vehicle Immobiliser System SRS 172 68 78 167 TOYOTA Hybrid System 54 Combination Meter Door Lock Control Headlight (w/ Daytime Running Light) Headlight (w//o Daytime Running Light) 182 134 80 84 Illumination Interior Light Key Reminder and Light Reminder Buzzer Navigation System 92 108 114 156 Power Window Radio and Player Seat Belt Warning Theft Deterrent 126 152 118 146 TOYOTA Hybrid System Wireless Door Lock Control 54 140 15A EFI Engine Control 68 15A THRO Engine Control 68 20A ABS NO.3 ABS 172 20A HV TOYOTA Hybrid System 54 30A ABS NO.2 ABS 172 30A CDS FAN Radiator Fan and Condenser Fan 186 30A HEAD Headlight (w/ Daytime Running Light) Key Reminder and Light Reminder Buzzer Light Auto Turn Off 80 114 104 30A RDI Radiator Fan and Condenser Fan 186 50A HTR Air Conditioning 188 Instrument Panel J/B (See Page 30) Fuse 5A ECU–IG System Page ABS Electric Tension Reducer EMPS Gateway System 172 162 164 160 Navigation System Radiator Fan and Condenser Fan Shift Lock 156 186 132 5A PANEL Illumination 92 7.5A ECU–B Air Conditioning Combination Meter 188 182 ∗ These are the page numbers of the first page on which the related system is shown. 2001 PRIUS (EWD414U) J POWER SOURCE (Current Flow Chart) Fuse 7.5A 7.5A 7.5A 10A 10A System Page Door Lock Control EMPS Gateway System Headlight (w/ Daytime Running Light) 134 164 160 80 Hybrid Vehicle Immobiliser System Interior Light Key Reminder and Light Reminder Buzzer Light Auto Turn Off 78 108 114 104 Power Window Theft Deterrent Wireless Door Lock Control 126 146 140 OBDII Engine Control Theft Deterrent 68 146 TAIL Key Reminder and Light Reminder Buzzer Light Auto Turn Off Taillight 114 104 88 Combination Meter Gateway System Navigation System Radio and Player 182 160 156 152 Remote Control Mirror Shift Lock SRS 130 132 167 ABS Air Conditioning Back–Up Light Combination Meter 172 188 102 182 Door Lock Control EMPS Engine Control Headlight (w/ Daytime Running Light) 134 164 68 80 Key Reminder and Light Reminder Buzzer Light Auto Turn Off Navigation System Power Window 114 104 156 126 Rear Window Defogger Seat Belt Warning Theft Deterrent TOYOTA Hybrid System 180 118 146 54 Turn Signal and Hazard Warning Light Wireless Door Lock Control 96 140 ECU–B ACC GAUGE 10A HTR Air Conditioning 188 10A SRS ACC SRS 167 ∗ These are the page numbers of the first page on which the related system is shown. 2001 PRIUS (EWD414U) J Fuse 15A System Page CIG Cigarette Lighter 122 15A STOP ABS Engine Control Shift Lock Stop Light 172 68 132 100 15A WASHER Wiper and Washer 120 20A PWR1 Power Window 126 30A DOOR Door Lock Control Theft Deterrent Wireless Door Lock Control 134 146 140 30A POWER Power Window 126 30A WIPER Wiper and Washer 120 40A DEF Rear Window Defogger 180 ∗ These are the page numbers of the first page on which the related system is shown. 2001 PRIUS (EWD414U) K CONNECTOR LIST A1 A2 A3 A4 A5 A6 BLACK DARK GRAY BLACK GRAY GRAY BLACK 1 1 1 2 1 2 3 4 2 A7 1 4 A8 1 2 3 4 5 6 7 8 9 8 9 10 11 12 13 14 10 11 12 13 14 15 16 17 18 A12 1 2 1 2 3 4 5 6 7 8 9 1011 1213141516171819 202122 A13 1 4 1 2 A16 1 2 A10 A14 A15 BLACK 1 2 2 A9 1 2 3 4 5 6 7 A11 2 3 2 5 BLACK 3 6 1 2 3 4 5 1 2 3 4 5 A17 A18 A19 A20 YELLOW YELLOW YELLOW YELLOW A B 1 2 3 4 5 1 2 3 1 2 3 4 5 6 A21 A22 BLACK B 1 2 4 5 6 1 2 3 4 5 6 7 8 9 1011121314151617 7 8 9 101112 7 8 9 101112 YELLOW A A B 1819 2021 22 23 2425 26 27 28 A23 A24 B1 B2 GRAY BLACK 1 2 3 4 1 1 2 1 2 1 2 2 1 5 6 7 8 2 9 10 11 12 B3 B4 B5 BLACK GRAY BROWN 1 1 2 3 4 7 8 9 10 11 12 5 6 B6 1 3 5 2 1 B7 BLACK 2 2 2001 PRIUS (EWD414U) 1 2 3 4 3 K B8 B9 B10 1 2 3 4 5 6 7 8 9 10 11 1213141516171819 20 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 B11 B12 BLACK 27 28 29 30 31 B13 B14 BLACK BLACK 1 2 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 17 18 19 20 21 20 21 22 16 17 22 23 24 B15 23 24 25 26 27 28 B16 BLACK 1 2 3 18 19 20 21 22 B17 4 1 B18 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 12 13 14 15 16 17 18 19 20 21 22 7 8 9 10 11 12 2 B19 B20 B21 BROWN 3 5 1 1 2 3 1 2 3 C1 C2 C3 BLACK BLACK YELLOW 1 2 1 2 1 2 C4 C5 C6 GRAY GRAY BLACK C7 C8 1 1 2 3 4 C9 1 2 1 1 C10 5 6 7 8 9 10 2 C11 GRAY 1 2 3 4 C12 BLACK 2 1 2 3 4 5 6 7 8 9 1011 1213141516171819 202122 1 2 3 4 5 1 2 3 4 5 6 7 8 9 6 7 8 9 10 10 11 12 131415 16 17 18 2001 PRIUS (EWD414U) 2 K CONNECTOR LIST C13 C14 D1 GRAY 2 1 2 3 4 5 6 7 8 1 1 2 3 4 5 6 9 10 1112131415 16 17 D2 D3 D4 D5 BLACK BLACK 1 2 3 1 2 3 4 5 6 7 8 9 10 11 1 16 15 14 13 12 11 10 9 2 12 13 14 15 16 17 18 19 20 8 7 6 5 4 3 2 1 D6 D7 D8 D9 D10 D11 BLACK 1 1 1 1 1 2 1 2 3 4 3 4 5 6 D12 D13 D14 E1 BLACK BLACK BLACK DARK GRAY 1 2 3 4 1 2 3 4 5 6 1 2 E3 1 2 3 4 5 6 E4 E5 1 2 E6 E7 GRAY 1 2 3 4 5 6 E2 1 2 1 2 BLACK 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 2001 PRIUS (EWD414U) 27 28 29 30 31 K E8 E9 E10 F1 BLACK BLACK BLACK YELLOW 1 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 1 2 3 4 5 8 9 10 11 12 13 14 15 16 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 17 18 19 20 21 20 21 22 16 17 22 23 24 23 24 25 26 27 28 2 6 7 18 19 20 21 22 F2 F3 F4 F5 F6 F7 YELLOW GRAY GRAY GRAY GRAY GRAY 1 2 1 2 1 2 1 2 1 2 1 F8 F9 GRAY GRAY 1 F10 F11 F12 (See Page 22) (See Page 22) (See Page 22) 2 1 2 3 2 4 5 F13 F14 F15 F16 F17 GRAY (See Page 22) (See Page 23) 1 1 2 2 F18 1 2 3 4 5 6 7 8 G1 H1 H2 H3 GRAY GRAY GRAY DARK GRAY (See Page 23) 1 2 1 2 3 4 5 6 7 1 3 2 3 1 2 3 4 8 9 10 11 12 13 14 H4 H5 H6 BLACK BLACK GRAY H8 H7 H9 1 1 2 3 4 5 6 1 1 2 3 4 5 2 3 4 5 2001 PRIUS (EWD414U) 1 2 3 4 5 1 2 3 4 K CONNECTOR LIST H10 H11 H12 H13 BLACK 1 2 3 4 5 16 17 7 8 9 1 2 3 4 5 6 1 2 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 8 9 10 11 12 13 14 15 16 20 21 22 13 14 15 17 18 19 20 21 6 7 1 2 3 4 5 6 8 9 10 11 12 13 14 15 18 19 20 21 22 BLACK 23 24 25 26 27 28 H14 H15 16 17 H16 3 4 5 6 7 22 23 24 H17 1 1 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 I1 I2 I3 I4 I5 BLACK GRAY BLACK GRAY BLACK 1 2 3 4 1 2 3 4 1 2 3 4 1 2 1 2 3 4 I6 I7 I8 I9 I10 GRAY BLACK GRAY GRAY GRAY 1 2 1 2 1 2 3 4 5 6 1 2 3 4 1 2 I11 I12 GRAY GRAY 1 2 3 4 5 6 1 2 3 4 I13 I14 1 1 5 6 7 8 I15 5 6 7 8 I16 I17 J1 J2 J3 1 2 3 4 5 6 7 8 J4 BLACK 1 2 12 A A A A A A A B A B 2001 PRIUS (EWD414U) A B A B A A B B C C D D E E F F K J5 A A B B C C J6 J6 J7 (w/ Daytime Running Light) (w/o Daytime Running Light) BLUE A A B C C A A B B B B C C A B A A B B B A A A A A A A A A A A A D D E E F F J8 J9 J10 GRAY GRAY BLACK J11 A A A A A A A A A A A A A A A A B B B C C C B B B C C C J13 A A J12 A A A A A B B C C A D D E E F F J14 J15 BLACK BLACK A A B B C C A A B B C C A A B B C C A A A B B B C C C C C D D E E F F D D D E E E D D D E E E D D D D E E E E E E E J17 A A J16 J18 J19 GRAY GRAY J20 A A A A A A A A A A A A A A A B B B C C C C C B B B C C C B B B C C C D D D D E E E E E E E A A A A J21 J22 J23 J24 BLACK BLACK GRAY A A A B B B C C C C C A A B B C C A A B B C C A A A A A A D D D D E E E E E E E D D D E E E D D D E E E B B B C C C J25 J26 J27 GRAY BLUE A A A A A A A A A B B B B C C C C A A B B C C C D D E E B B B C C C D D D E E E E F F F F F F F F G G G H H H H 2001 PRIUS (EWD414U) K CONNECTOR LIST J28 J29 J30 J31 BLUE BLACK BLACK BLACK A A B B C C C D D E E A A B B C C A A B B C C F F F F G G G H H H H D D D E E E D D D E E E A A A A L1 J32 J33 K1 GRAY GRAY DARK GRAY A A A A A A A A A A A A B B B C C C B B B C C C 1 1 L3 L4 1 2 2 3 4 5 6 L5 L6 M1 GRAY 1 L2 GRAY BLACK 2 1 1 2 2 1 1 2 3 4 5 M2 M3 M4 GRAY GRAY GRAY 1 2 3 4 5 6 1 2 3 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 M6 M7 N1 BLUE BLUE GRAY 12 3 456 7 8 1 2 3 4 5 1 2 6 7 8 9 10 N4 M5 O1 P1 N2 N3 1 2 3 4 5 6 7 8 9 1 2 3 4 5 10 11 12 13 14 15 16 17 18 6 7 8 9 10 P2 P3 P4 BLACK 1 1 2 1 1 P5 3 4 5 6 7 8 9 P6 1 P7 P8 GRAY 1 2 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 2001 PRIUS (EWD414U) 2 1 2 3 4 K P9 P10 BLUE BLACK P11 P12 P13 1 2 1 2 1 2 1 2 1 2 3 4 8 5 6 7 3 4 9 10 11 12 13 14 15 16 17 18 19 20 P14 5 6 P15 R1 R2 R3 BLACK 1 2 1 1 2 1 2 R4 2 R5 1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5 6 7 8 9 10 R10 1 2 3 4 5 6 R11 R6 R7 1 2 1 2 3 4 5 6 S1 3 4 5 6 7 8 9 10 R8 R9 3 4 1 1 5 6 2 2 S2 S3 S4 GRAY 2 1 2 1 4 3 4 3 6 5 6 5 YELLOW 1 2 3 4 5 6 1 2 3 4 S5 S6 S7 YELLOW YELLOW YELLOW 1 3 S8 1 2 3 4 2 4 S9 1 1 2 3 4 1 2 S10 1 2 3 4 5 6 7 1 2 S11 S12 T1 T2 BLACK BLACK 1 1 1 1 1 2 T3 T4 T5 BLACK 1234 T6 U1 BLACK 1 2 3 4 12 3 456 78 5 6 7 8 9 10 11 12 2001 PRIUS (EWD414U) 12 1 2 3 4 K CONNECTOR LIST V1 V2 V3 V4 V5 BLACK BLUE BROWN BLACK BLACK 1 2 3 1 1 2 3 2 1 2 1 V6 W1 W2 W3 W4 BLUE BLACK BLACK GRAY DARK GRAY 1 1 2 3 2 1 2 1 2001 PRIUS (EWD414U) 2 1 2 2 W5 1 2 3 4 5 MEMO 2001 PRIUS (EWD414U) L PART NUMBER OF CONNECTORS Code Part Name Part Number Code Part Name Part Number B20 Buckle SW and Tension Reducer LH B21 Buckle SW RH and Seat Belt Warning Occupant Detection Sensor 90980–11471 C1 Camshaft Position Sensor 90980–10947 C2 Camshaft Timing Oil Control Valve 90980–11162 C3 Circuit Breaker Sensor 90980–11898 90980–11070 C4 Converter 90980–10942 A1 A/C Condenser Fan Motor 90980–11237 A2 A/C Magnetic Clutch and Lock Sensor 90980–10942 A3 A/C Triple Pressure SW (A/C Dual and Single Pressure SW) 90980–10943 A4 ABS Speed Sensor Front LH A5 ABS Speed Sensor Front RH A6 Ambient Temp. Sensor A7 A/C Amplifier 90980–11911 C5 Converter 90980–11963 A8 A/C Amplifier 90980–11913 C6 Crankshaft Position Sensor 90980–12028 90980–11927 C7 Center Cluster SW 90980–10801 C8 Cigarette Lighter 90980–10760 C9 Cigarette Lighter Illumination 90980–11148 90980–11003 A9 A/C Amplifier A10 A/C Room Temp. Sensor A11 A/C Solar Sensor A12 A/C Thermistor C10 Combination Meter 90980–11927 A13 Accel Position Sensor 90980–11144 C11 Combination Meter 90980–11923 A14 Air Inlet Control Servo Motor 90980–11921 C12 Combination SW 90980–11594 A15 Air Mix Control Servo Motor C13 Combination SW 90980–11672 A16 Air Vent Mode Control Servo Motor C14 Combination SW 90980–11616 A17 Airbag Sensor Assembly 90980–11869 D1 DC Motor 90980–10838 A18 Airbag Sensor Assembly 90980–11872 D2 Data Link Connector 3 90980–11665 A19 Airbag Sensor Assembly 90980–11867 D3 Daytime Running Light Relay 90980–12034 A20 Airbag Squib (Front Passenger Airbag Assembly) 90980–11884 D4 Diode (Door Courtesy) 90980–11251 D5 Diode (Daytime Running Light) 90980–10962 A21 Airbag Squib (Steering Wheel Pad) 90980–10850 D6 Door Courtesy SW Front LH A22 Ashtray Illumination 90980–12111 D7 Door Courtesy SW Front RH A23 ABS Speed Sensor Rear LH D8 Door Courtesy SW Rear LH 90980–11919 90980–11909 90980–11060 A24 ABS Speed Sensor Rear RH B1 Brake Actuator 90980–11087 B2 Brake Actuator 90980–11161 B3 Brake Actuator 90980–11698 B4 Brake Fluid Level Warning SW 90980–11207 B5 Back–Up Light Relay 82660–20340 B6 Blower Motor 90980–10214 B7 Blower Motor Linear Controller 90980–11676 B8 Body ECU 90980–11971 B9 Body ECU 90980–11973 B10 Brake ECU B11 90980–10871 D9 Door Courtesy SW Rear RH D10 Door Lock Control SW Front RH D11 Door Lock Motor and Door Unlock Detection SW Rear LH D12 Door Lock Motor and Door Unlock Detection SW Rear RH D13 Door Lock Motor, Door Key Lock and Unlock SW and Door Unlock Detection SW Front LH D14 Door Lock Motor, Door Key Lock and Unlock SW and Door Unlock Detection SW Front RH 90980–11935 E1 Engine Coolant Temp. Sensor Brake ECU 90980–11476 E2 Engine Hood Courtesy SW 90980–11189 B12 Brake ECU 90980–11637 E3 EMPS ECU 90980–12012 B13 Brake ECU 90980–11638 E4 EMPS ECU 90980–11579 B14 Brake Warning Buzzer 90980–10906 E5 EMPS ECU 90980–12120 B15 Battery Blower Motor 82824–47130 E6 EMPS ECU 90980–11923 B16 Battery Blower Motor Controller 90980–11676 E7 Engine Control Module 90980–11421 B17 Battery ECU 90980–11392 E8 Engine Control Module 90980–11476 B18 Battery ECU 90980–11424 E9 Engine Control Module 90980–11637 B19 Battery Fan Relay 82660–20340 Note: Not all of the above part numbers of the connector are established for the supply. 2001 PRIUS (EWD414U) 90980–10797 90980–11150 90980–11858 90980–10737 L Code Part Name E10 Engine Control Module F1 Front Airbag Sensor LH F2 Front Airbag Sensor RH F3 Front Parking Light LH F4 Front Parking Light RH Part Number Code 90980–11638 I10 Inverter 90980–10891 I11 Inverter 90980–10988 I12 Inverter 90980–10897 I13 Inverter 90980–11943 I14 Inverter 90980–11944 I15 Ignition SW 90980–11615 I16 Interior Light 90980–10860 I17 Interlock SW 90980–11918 J1 Junction Connector 90980–10976 J2 Junction Connector J3 Junction Connector J4 Junction Connector J5 Junction Connector 90980–11856 90980–11162 F5 Front Side Marker Light LH F6 Front Side Marker Light RH F7 Front Turn Signal Light LH F8 Front Turn Signal Light RH F9 Front Wiper Motor F10 Fusible Link Block No.1 F11 Fusible Link Block No.1 F12 Fusible Link Block No.1 F13 Fusible Link Block No.1 F14 Front Door Speaker LH F15 Front Door Speaker RH F16 Fuel Pump and Fuel Sender 90980–12164 F17 Fusible Link Block No.2 90980–10916 F18 Fusible Link Block No.2 90980–11775 G1 Gateway ECU 90980–11911 H1 Headlight LH H2 Headlight RH H3 Heated Oxygen Sensor (Bank 1 Sensor1) 90980–11028 H4 Horn 90980–10619 H5 Hydraulic Booster 90980–10939 H6 Hydraulic Booster 90980–10946 H7 Hazard Warning SW 90980–11319 H8 Hazard Warning SW 90980–11921 H9 Heated Oxygen Sensor (Bank 1 Sensor 2) 90980–11028 H10 Hybrid Vehicle Control ECU 90980–11638 H11 Hybrid Vehicle Control ECU 90980–11637 H12 Hybrid Vehicle Control ECU 90980–11586 H13 Hybrid Vehicle Control ECU 90980–11476 H14 Hybrid Vehicle Control ECU 90980–11421 H15 High Mounted Stop Light 90980–11060 H16 Hybrid Vehicle Battery H17 Hybrid Vehicle Battery I1 Ignition Coil and Igniter No.1 I2 Ignition Coil and Igniter No.2 I3 Ignition Coil and Igniter No.3 I4 Ignition Coil and Igniter No.4 I5 Injector No.1 I6 Injector No.2 I7 Injector No.3 I8 Injector No.4 I9 Inverter 90980–11019 90980–11599 – 90980–11775 90980–10935 90980–11314 – 90980–11885 90980–11875 Part Name Part Number 90980–11742 90980–11661 Junction Connector (w/ Daytime Running Light) 90980–11542 Junction Connector (w/o Daytime Running Light) 90980–11529 J7 Junction Connector 90980–10803 J8 Junction Connector J9 Junction Connector J10 Junction Connector 90980–11398 90980–10976 J6 90980–11661 J11 Junction Connector J12 Junction Connector J13 Junction Connector J14 Junction Connector J15 Junction Connector J16 Junction Connector 90980–11915 J17 Junction Connector 90980–10976 J18 Junction Connector J19 Junction Connector J20 Junction Connector J21 Junction Connector J22 Junction Connector J23 Junction Connector J24 Junction Connector J25 Junction Connector J26 Junction Connector J27 Junction Connector J28 Junction Connector J29 Junction Connector J30 Junction Connector J31 Junction Connector J32 Junction Connector J33 Junction Connector K1 Knock Sensor 90980–11166 L1 Light Control Rheostat 90980–10797 90980–11034 2001 PRIUS (EWD414U) 90980–11661 90980–11661 90980–11915 90980–11661 90980–11915 90980–11396 90980–11661 L PART NUMBER OF CONNECTORS Code Part Name L2 License Plate Light LH L3 License Plate Light RH L4 Luggage Compartment Door Unlock SW L5 Luggage Compartment Light L6 Part Number Code Part Name Part Number S4 Side Airbag Sensor LH S5 Side Airbag Sensor RH 90980–11212 S6 Side Airbag Squib LH 90980–11148 S7 Side Airbag Squib RH Luggage Compartment Light SW 90980–11097 S8 System Main Relay M1 Mass Air Flow Meter 90980–11317 S9 System Main Relay M2 Motor Generator No.1 90980–11658 S10 System Main Relay M3 Motor Generator No.2 90980–11034 S11 System Main Relay M4 Motor Generator No.2 90980–11143 S12 System Main Relay M5 Multi Display 90980–11911 T1 Theft Deterrent Horn M6 Multi Display 90980–11923 T2 Throttle Control Motor 90980–11162 M7 Multi Display 90980–10799 T3 Throttle Position Sensor 90980–10711 N1 Noise Filter (Ignition) 90980–10843 T4 Transponder Key Computer 90980–11475 N2 Navigation ECU 90980–11973 T5 Turn Signal Flasher Relay 90980–10799 N3 Navigation ECU 90980–11923 T6 Tension Reducer Solenoid 90980–11918 U1 Unlock Warning SW and Key Interlock Solenoid 90980–10795 V1 Vacuum Sensor (HC Adsorber and Catalyst System) 90980–10845 V2 VSV (EVAP) 90980–11156 V3 VSV (HC Adsorber and Catalyst System) 90980–11149 V4 Vapor Pressure Sensor 90980–11143 V5 VSV (Canister Closed Valve) 90980–11156 V6 VSV (Parge Flow Switching Valve) 90980–11859 W1 Washer Motor 90980–10981 W2 Water Pump Motor (A/C) 90980–10887 W3 Water Pump Motor (Inverter) 90980–11003 W4 Water Temp. SW 90980–11235 W5 Wireless Door Control Receiver 90980–11909 90980–11148 N4 Noise Filter (Rear Window Defogger) 90980–11259 O1 Oil Pressure SW 90980–11363 P1 Park/Neutral Position SW 90980–11535 P2 Parking Brake SW 90980–11147 P3 PTC Heater 90980–10903 P4 PTC Heater 90980–10867 P5 Personal Light 90980–11212 P6 Power Window Control SW Front RH P7 Power Window Control SW Rear LH P8 Power Window Control SW Rear RH P9 Power Window Master SW 90980–11469 P10 Power Window Motor Front LH 90980–11011 P11 Power Window Motor Front RH P12 Power Window Motor Rear LH P13 Power Window Motor Rear RH P14 Pretensioner LH 90980–11884 P15 Pretensioner RH 90980–11862 R1 Radiator Fan Motor 90980–11237 R2 Radio and Player 90980–10996 R3 Radio and Player 90980–10997 R4 Radio and Player 90980–10903 R5 Remote Control Mirror SW 90980–11657 R6 Rear Combination Light LH R7 Rear Combination Light RH R8 Rear Speaker LH R9 Rear Speaker RH R10 Remote Control Mirror LH R11 Remote Control Mirror RH S1 Steering Shaft Torque Sensor 90980–10942 S2 Shift Lock ECU 90980–11488 S3 Stop Light SW 90980–11118 90980–10797 90980–10860 90980–11011 90980–10935 90980–11587 Note: Not all of the above part numbers of the connector are established for the supply. 2001 PRIUS (EWD414U) 90980–11857 90980–11864 90980–11529 82675–36050 – 90980–10619 L Code Part Name Part Number Code 2001 PRIUS (EWD414U) Part Name Part Number M OVERALL ELECTRICAL WIRING DIAGRAM 2001 PRIUS (EWD414U) [A] : System Title [B] : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black W = White BR = Brown L = Blue V SB = Sky Blue = Violet R = Red O = Orange LG = Light Green P Y = Pink = Yellow [F] : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. Example: GR = Gray G = Green The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Example: ,,,, ,,,, 3C indicates ,,,, that it is inside ,,,, Junction Block ,,,, ,,,,No.3 ,,,, L–Y [G] : Indicates related system. 2001 PRIUS (EWD414U) L (Blue) [H] : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows ( ). Outside numerals are pin numbers. Y (Yellow) [C] : The position of the parts is the same as shown in the wiring diagram and wire routing. [D] : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example : Numbered in order from upper left to lower right Numbered in order from upper right to lower left Female [I] Male ( ) : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. [J] : Indicates a shielded cable. Female Male The numbering system for the overall wiring diagram is the same as above [E] : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example : [K] : Indicates and located on ground point. [L] : The same code occuring on the next page indicates that the wire harness is continuous. Indicates Relay Block No.1 M SYSTEMS LOCATION SYSTEMS LOCATION 2001 PRIUS (EWD414U) ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19–3 Navigation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14–5 Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24–2 Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1~24–1 Back–Up Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2 Power Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18–2 Cigarette Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–4 Radiator Fan and Condenser Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22–3 Combination Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23–2 Radio and Player . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14–2 Door Lock Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–2 Rear Window Defogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22–2 Electric Tension Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–4 Remote Control Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–2 EMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–3 Seat Belt Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4 Engine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3 Shift Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–3 Gateway System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14–8 SRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21–2 Headlight (w/ Daytime Running Light) . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2 Stop Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4 Headlight (w/o Daytime Running Light) . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 Taillight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–2 Theft Deterrent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17–2 Hybrid Vehicle Immobiliser System . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–16 TOYOTA Hybrid System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 Illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2 ∗ Charging ∗ Cruise Control ∗ Regenerative Brake Interior Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–3 Turn Signal and Hazard Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 Key Reminder and Light Reminder Buzzer . . . . . . . . . . . . . . . . . . . . . . 9–2 Wiper and Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–3 Light Auto Turn Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3 Wireless Door Lock Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16–2 M OVERALL ELECTRICAL WIRING DIAGRAM SYSTEM INDEX (Cont. next page) 1 PRIUS ELECTRICAL WIRING DIAGRAM P ow er S ource T O Y O T A H ybrid S ystem 1 3 2 B–R 4 B–R G–Y G–Y L–R L–R W–G W A B C D L–Y W–G W–B ACC 2 AM1 IG1 4 E B–Y ST1 B–W 7 AM2 W–R IG2 6 B–W B–W ST2 8 R–W R–W 2 2C GR–B 2 2G I15 IGNITION SW 6 2D 3 2B 5 2A 22 A 14 IK1 MPX– GR MPX2 CRUISE CHARGE OUTPUT CONTROL 13 MPX– E10 ENGINE CONTROL MODULE 14 GR–L 5 11 B–W MPD2 IG1 RELAY 2 MPD1 3 GR–B 14 A 8 2K 8 2D C10 A , C11 B 3 B 4 COMBINATION METER MP2+ GR 1 2H L 11 2G G1 GATEWAY ECU 4 5 2B W–B W–B W B–W B8 BODY ECU 16 2 B 10A GAUGE 5A AM1 1 MPX+ 7 2A A7 A/C AMPLIFIER 11 GR W F17 A , F18 B 21 A W 1 W–B 3 1J W3 WATER PUMP MOTOR (Inverter) B–W W–B 1 A 3 1K B–W 1 B 2 2 W–B 1 B 120A MAIN 3 W–B B–G B–R 100A DC/DC F10 A , F11 B , F12 C , F13 D 1 D FUSIBLE LINK BLOCK NO. 1 1 C 5A DC/DC–S IG2 RELAY B B 1 1 1A 2 1B 1 1B 2 A 15A DOME 15A AM2 20A HV 10A BATT FAN 5 MPX+ GR–B 2 1A 7 1J 4 2A L 9 1J 15 W–G 8 1J B–W B–Y W–R L–R G–Y 2001 PRIUS (EWD414U) 11 1F L L–Y 1 2G F G 6 2B W BR FUSIBLE LINK BLOCK NO. 2 A BATTERY W–B J11 JUNCTION CONNECTOR W–B ID Cowl side panel LH IH H I Right kick panel M B B C A C14 CRUISE CONTROL SW [COMB. SW] W–B B–W 2001 PRIUS (EWD414U) Cowl side panel RH L W–B W–B W–B IG A L–R 5 6 P1 PARK/NEUTRAL POSITION SW 2 1 7 LG–R J17 JUNCTION CONNECTOR G A13 ACCEL POSITION SENSOR 1 4 8 JUNCTION CONNECTOR J24 A , J25 B 9 A A 3 A A A B E A D B E E W–B W–B W–B W B–R J22 A , J23 B A Y EP2 W A A 2 R A A 4 B A B 3 L EP1 VCP2 VPA2 L–W W–B A B 5 (*1) JUNCTION CONNECTOR ECC 6 B VCP1 VPA1 E A L–R G–Y EOM 5 E * 1 : Shielded JUNCTION CONNECTOR A B 4 W–B CCS VSFT SFT GSFT 12 E 11 E 21 E 8 W–B J18 A , J19 B S3 STOP LIGHT SW B–W CANCEL SET/COAST RES/ACC W–B From Stop Light SW <3–4> 6 ID1 3 CRUISE W–B 5 W–B GND1 31 D HYBRID VEHICLE CONTROL ECU VCP1 VPA1 EP1 VCP2 VPA2 EP2 P N D B R 13 D 14 D 12 D 23 D 15 D 22 D 15 E 13 E 23 E 22 E 14 E H10 C , H11 A , H12 B , H13 E , H14 D 7 J21 JUNCTION CONNECTOR W–B C A 4 GND2 STP 24 D 1 D G–W CCS 16 D 6 TO Y O T A H y brid S ys tem B A (Cont. next page) W–B G F E D C W–B I H W–B R–W IGSW 7 E B–W G ST2 6 E ST1– 2 D B–Y B–W W–B W L–R G–Y 5 R–W F E D C B A B–R 1 PRIUS (Cont’ d) M OVERALL ELECTRICAL WIRING DIAGRAM W–B W–B R–B W–B L–B (*1) R W W–B B–W JUNCTION CONNECTOR J24 A , J25 B 1 PRIUS (Cont’ d) (Cont. next page) TO Y O T A H y brid S ys tem 9 A B * 1 : Shielded 11 10 12 G–Y G–Y L–R L–R A B H10 C , H11 A , H12 B , H13 E , H14 D ETH+ ETH– 28 D 27 D HTE+ HTE– 19 D 29 D ESTP SPDO GO 8 D 6 D 10 B GSNG 11 C GSN 4 C GRF 10 C GRFG 17 C HYBRID VEHICLE CONTROL ECU GCS GCSG GMTG GMT MSNG MSN 5 C 12 C 8 C 1 C 20 C 13 C MCSG MRF 21 C 19 C MRFG 18 C MMTG 9 C MMT 2 C (*1) L P (*1) G O R–Y BR Y (*1) (*1) (*1) W–B GR R–W W B L (*1) P R G B–R G–W BR Y W B R (*1) G (*1) (*1) (*1) B (*1) B 2 A GSN 1 A GRF 6 A GRFG 3 A GCS 8 A 9 A GCSG GMTG 4 A GMT 5 B MSNG 2 B MSN 3 B 6 B MCS MCSG 1 B MRF 4 B 3 C MRFG MMTG A A A W–B A (*1) M3 B , M4 C MOTOR GENERATOR NO. 2 J7 JUNCTION CONNECTOR M2 A MOTOR GENERATOR NO. 1 A A W–B W–B G F MMT W W–B B–R W F E 1 B (*1) C B GSNG (*1) C B 7 A (*1) B A W–B W–B B A W–B E B–R W–B W–B W–B J8 A , J9 B W–B JUNCTION CONNECTOR B A (*1) (*1) (*1) D D (*1) (*1) W–B J18 JUNCTION CONNECTOR C C (*1) (*1) 2001 PRIUS (EWD414U) To Engine Control Module <2–13><2–14> B MCS 14 C G H W–B W–B J1 JUNCTION CONNECTOR Cowl side panel LH A A W–B I IE M 2001 PRIUS (EWD414U) W B–R W–B W–G Y To A/C Amplifier <24–6> Y I L–O W–B 14 IE1 B GND 6 B W 3 C 4 C G M–IVA M–IVB M–IWB VB 5 C Y AMD IDH 1 B 2 A (*1) 1 C 1 B 3 B 2 B 4 A 5 A G–IWB G–IWA G–SDOWN G–INVT 4 B 2 A INVERTER 1 A 6 A W–G G–WU G–VU G–UU G–GINV 3 A I 9 D , I10 C , I11 A , I12 B , I13 E , I14 F M–IWA G–IVA G–IVB 2 C R W B 6 D B H W 2 D W B–R R 1 D G G G 3 D (*1) 2 IH1 L 5 D G S 3 A 4 D W CONVERTER 7 C R IGCT M–SINV M–SDOWN M–INVT M–WU M–UU M–VU M–GINV 1 IH1 M–FINV 8 C (*1) C4 A , C5 B W–G 5 B G–SINV 7 B GSIV 15 A MFIV 14 A GWU GVU GUU GIVG 3 A 2 A 1 A 27 A GFIV 24 A 8 B G–FINV ILK 4 E 4 IH1 2 1 10 IF1 16 B NODD W–G 4 A G W–G L–R G–Y 1 E CEI 1 F W–R O(*2) O(*2) I17 INTERLOCK SW CVRSW CBI 6 C V–R IGCT R 1 A Y (*1) (*1) V–R F GSDN 12 A B (*1) W–G GIT 23 A L GIWB GIWA 18 A 28 A B (*1) MIT MWU MUU MVU MIVG 11 A 6 A 4 A 5 A 26 A 15 * 1 : Shielded * 2 : High Voltage(273. 6V) O E W–G W–G W–G (*1) MSDN 13 A Y MSIV 21 A H10 C , H11 A , H12 B , H13 E , H14 D HYBRID VEHICLE CONTROL ECU MIVA MIVB MIWB VB MIWA GIVA GIVB 16 A 7 A 17 A 20 A 25 A 19 A 8 A 14 G D W–G 13 IA1 +B2 5 D W–G 12 IA1 NODD 4 B L–O +B1 4 D L–R G–Y 13 TO Y O T A H y brid S ys tem F E D C B A (Cont. next page) O C B A 1 PRIUS (Cont’ d) M OVERALL ELECTRICAL WIRING DIAGRAM W–G 1 PRIUS (Cont’ d) (Cont. next page) TO Y O T A H y brid S ys tem 17 A B * 1 : Shielded * 2 : High Voltage(273. 6V) 19 18 20 G–Y G–Y L–R L–R A B H10 C , H11 A , H12 B , H13 E , H14 D WFSE 9 D TC 10 D HAO 9 E HAI 10 E CON1 13 B CON2 2 B CON3 1 E GB 26 D IB 25 D HTB– 30 D BTH+ 18 D BTH– 17 D ABFS 3 E FCVC 7 D L B–W From Airbag Sensor Assembly<21–3> From Transponder Key Computer<2–16> R G 2 IF2 4 IF2 3 IF2 6 IB1 B–L R–W G 5 A To Combination Meter <23–2> 10 IB1 (*1) R B 4 A V LG 1 IF2 W 3 A W–G C V–W 5 IF2 2 B–L 1 R–W G (*1) R B W 1 B HTB+ 20 D 19 IE1 O(*2) 1 C SPDI 8 B V–W G–R P GR V 2001 PRIUS (EWD414U) To Data Link Connector 3 <2–5><2–6> O(*2) BR–B 11 IF1 C3 CIRCUIT BREAKER SENSOR 9 IH1 P GR V P 8 IH1 E AS1 15 B W–G 10 ID1 D AS1G 14 B Y–R Y W–L P–B P C SIL 21 D HYBRID VEHICLE CONTROL ECU HTD+ HTD– DTH+ DTH– 20 E 19 E 18 E 2 E From Brake ECU <19–9> S 8 A , S 9 B , S10 C , S11 D , S12 E SYSTEM MAIN RELAY 1 A 7 A 2 A 6 A 1 D 1 E O(*2) O(*2) O(*2) O(*2) W–B W–B W–B E F W–B W–B F D To Data Link Connector 3 <2–6> W–R W C A C A 3 IF1 J32 A , J33 B W B–L R–W G R B W W–R Y–R Y–B B B Y JUNCTION CONNECTOR B B W–B W–B W–B BJ 22 A Right side of rear pillar 4 B 10 B 3 B 2 A 6 A 7 A 18 A 19 A 17 A 16 A 8 A B17 A , B18 B BATTERY ECU M 2001 PRIUS (EWD414U) F 14 2 4 5 6 7 8 9 W G–W R L–R G Y L P L–O O V–Y HYBRID VEHICLE BATTERY H16 A , H17 B 1 3 4 5 6 7 8 9 10 1 A 8 B 2 B W–B L L–B P–L LG–R L–W Y–B LG LG–B GR GR–B BI B B W–B Left side of rear pillar 9 B 1 4 L EC J32 JUNCTION CONNECTOR Engine compartment left W–B B16 BATTERY BLOWER MOTOR CONTROLLER B15 M BATTERY BLOWER MOTOR 2 1 2 1 W–B BATTERY ECU 2 2 3 L LG–R 5 3 7 IH1 A IE A A A Cowl side panel LH J1 JUNCTION CONNECTOR J7 JUNCTION CONNECTOR B19 BATTERY FAN RELAY W–B B17 A , B18 B 24 JUNCTION CONNECTOR 11 G 23 J2 A , J3 B 10 G–Y 22 G–Y 21 LG–R 20 G–Y L–B 18 2 L–R 17 2 2 L 16 5 IH1 2 1 L–B 3 SENSOR 5 2 24 * 2 : High Voltage(273. 6V) W–B 15 BUSBER MODULE HYBRID VEHICLE BATTERY O (*2) 1 B B A 3 G–Y BUSBER MODULE HYBRID VEHICLE BATTERY O (*2) SERVICE PLUG O (*2) 1 A W–B B A B B G–Y O(*2) G–Y 4 IA1 MREL 7 B 23 IGCT RELAY E BATT 3 D W–G O(*2) HYBRID VEHICLE CONTROL ECU H10 C , H11 A , H12 B , H13 E , H14 D 22 O D W–G L–R G–Y 21 TO Y O T A H y brid S ys tem L–R C B A 1 PRIUS (Cont’ d) M OVERALL ELECTRICAL WIRING DIAGRAM L–R L–B W–B G–Y G R W R W B B L MEMO 2001 PRIUS (EWD414U) 2 PRIUS W–L R–G W–B 5A AM1 W 7. 5A OBDII 7. 5A ECU–B 2001 PRIUS (EWD414U) W–B B–G 120A MAIN Near the fuel tank W–B 10A GAUGE IE W–B W–B W–B Cowl side panel LH Cowl side panel RH J17 JUNCTION CONNECTOR IG W–B BL J1 JUNCTION CONNECTOR A 7 A A B B 22 A 14 A 6 2B 7 2A IH BR ID L J11 JUNCTION CONNECTOR W–B A W–B M 3 G–R 19 IA1 R–W 8 BC1 F16 FUEL PUMP B C A 3 1A 4 1A Right kick panel 4 MP2+ MPX+ 11 3 B 2 B A7 A/C AMPLIFIER Cowl side panel LH A IG2 RELAY J7 JUNCTION CONNECTOR G–R C A 13 1F B A A B 10 1A 4 B L J18 JUNCTION CONNECTOR 14 IA1 4 IA2 2 1 GR A A W–B 1 1F 3 5 15 MPX+ MPX– 16 COMBINATION METER BATTERY F18 FUSIBLE LINK BLOCK NO. 2 12 1F 1 G–R B–R 1 5 EFI RELAY 1 D 3 1K 2 2 B–R F11 B , F12 C , F13 D 2 1B 3 3 4 G–R GR GR B–W B–W B W–L R–G W–B B B GR–B G–R G–R R–W C10 A , C11 B FUSIBLE LINK BLOCK NO. 1 IG1 RELAY 100A DC/DC 1 C 5 2A 15A THRO 1 2 1A GR CIR OPN RELAY 8 2D 15A EFI 5 3 1J B–W B–W G–R B 5 15A AM2 11 2G D J26 JUNCTION CONNECTOR W–L D GR–B 8 2K 2 3 5 2B 3 B8 BODY ECU 1 B W–G 1 2H B–Y 1 W–R 9 1J 8 1A B–W B–W 6 2D I15 IGNITION SW IG2 6 ST2 B–Y 3 2B 1 2G 7 AM2 ST1 IG1 4 B–W 9 2D 2 2C W–R 2 AM1 ACC 2 E ngine C ontrol GR 5 2C 1 P ow er S ource O N M L K J I H G F E D C B A (Cont. next page) M OVERALL ELECTRICAL WIRING DIAGRAM MALFUNCTION INDICATOR LAMP L B JUNCTION CONNECTOR J4 A , J5 B W–B 2 PRIUS (Cont’ d) (Cont. next page) E ngine C ontrol A B C D E F G 5 R–G * 1 : Shielded 7 6 8 B–R B B B–W B–W B–W B–W B–W B–W B–W B–W A B C D E GR GR W–B W–B W–B W–B B–W W–B B–W W–B B–W W–B G–R B–W H R–G W–L P–B 3 2 7 25 A IGT1 12 A IGF BATT 3 B FC 9 B MREL 25 C MPX1 14 D +B 4 B EVP1 22 B THW MOPS 14 B 12 B 5 2 2 MPD1 1 B B BR 4 1 O1 OIL PRESSURE SW MPD2 Y–B M1 MASS AIR FLOW METER E1 ENGINE COOLANT TEMP. SENSOR 1 W 2 (*1) B B 3 BR GR–B R GR–B 4 B From EMPS ECU<20–4> EVG 19 B G R–B GR–G G1 GATEWAY ECU B From Brake ECU<19–12> VG 10 B V2 VSV(EVAP) B 11 14 ID2 GR–G IGT4 ENGINE CONTROL MODULE R–L B GR–L G–R G–R R–W 1 B 2 14 A IGT3 THA 29 A G–R B 13 A IGT2 E 7 A , E 8 B , E 9 C , E10 D 3 Y MPX2 G +BM 4 B–R W 6 A 13 D 11 A B–R Y–G W GR 6 D TC GR G–R 6 C 2 B–R From Airbag Sensor Assembly<21–3> BR M P–B W W BR W–B Y P L W–L SIL C G–R J16 JUNCTION CONNECTOR K GR–G I J From Battery ECU<1–20> From Hybrid Vehicle Control ECU<1–17> E 8 C 3 ID1 R–W P–B C B C From EMPS ECU <20–4> C B E W–L 5 P–B 4 C From Brake ECU <19–11> 12 SG E W–L 15 CG From Hybrid Vehicle Control ECU<1–17> 8 OP2 C P–B WFSE Y–R GR–G 14 OP3 A A J22 A , J23 B TS E A A JUNCTION CONNECTOR D2 DATA LINK CONNECTOR 3 W–L SIL 3 1 B–R 13 AB TC W 6 OP1 W 11 BAT 4 B–R B–R 16 1 I4 IGNITER COIL AND IGNITER NO. 4 4 I3 IGNITER COIL AND IGNITER NO. 3 2 C 1 B–R E 3 2 ID1 P–B J16 JUNCTION CONNECTOR 4 I2 IGNITER COIL AND IGNITER NO. 2 1 ID1 W–L E B–Y From Multi Display<14–7> E P–B J26 JUNCTION CONNECTOR P–B 2001 PRIUS (EWD414U) From Airbag Sensor Assembly<21–3> E P–B 1 I1 IGNITER COIL AND IGNITER NO. 1 B–R W–L W E BR B B 14 IO1 N B A J24 JUNCTION CONNECTOR W–B EB (*1) W–B A BR O B W–B Engine block EA F G H I Engine block M 2001 PRIUS (EWD414U) I (*1) V3 VSV(HC Adsorber and Catalyst System) B–W B B V–W BR BR BR 4 Y–R B V1 VACUUM SENSOR (HC Adsorber and Catalyst System) JUNCTION CONNECTOR E2 BR T3 THROTTLE POSITION SENSOR B 2 4 3 H3 HEATED OXYGEN SENSOR (Bank 1 Sensor 1) 1 1 IK1 D A E B B E B 12 IP1 JUNCTION CONNECTOR B BR BR OCV+ 23 A J22 A , J23 B E B GE01 30 A 2 4 * 1 : Shielded HT1B 1 7 D B–W B–R R–G BR BR (*1) BR BR BR (*1) (*1) H9 HEATED OXYGEN SENSOR (Bank 1 Sensor 2) 3 11 D OX1B OCV– 24 A Y B JUNCTION CONNECTOR V4 VAPOR PRESSURE SENSOR L J8 A , J9 B BR Y–R Y–R P–L B B Y–R W BR 3 Y–R 6 IK1 P–L (*1) 7 IK1 22 IE1 2 IE1 W 1 IE1 E11 16 D BR 1 J24 A , J25 B 1 Y–R 2 L–R 3 OX1A 12 D BR C A VTA2 VTA1 HT1A 1 D M+ 8 A 1 2 12 (*1) H B–W 3 P 2 E2 18 B M– 7 A (*1) C A VTA2 21 B CCV 13 C 2 (*1) 1 V–W VC 1 23 B VTA TBP BR C A I6 INJECTOR NO. 2 4 BC1 L–R BR 7 BC1 I7 INJECTOR NO. 3 3 BC1 I8 INJECTOR NO. 4 2 I5 INJECTOR NO. 1 15 IO1 Y–R PTNK 22 C #40 (*1) 2 B–W P–L 9 IO1 Y W 6 IO1 VC B–W 2 B B–R HCLS L–W #30 R–W 14 C B–W B–R #20 B–W E 7 A , E 8 B , E 9 C , E10 D B #10 B–W L ENGINE CONTROL MODULE 1 P 11 C 6 BC1 1 2 T2 THROTTLE CONTROL MOTOR L IGSW N1 NOISE FILTER (Ignition) 2 A V6 VSV(Parge Flow Switching Valve) 2 JUNCTION CONNECTOR 2 BC1 B–R 1 5 BC1 L 1 A 1 1 BC1 V5 VSV(Canister Closed Valve) 6 B 2 1 A B B 5 B 2 1 C A A B C2 CAMSHAFT TIMING OIL CONTROL VALVE 9 D 2 1 B–W J4 A , J5 B 2 1 B–W 11 Y–R G–Y G HCC B–W B B B B–W C A B–W B C A B–W 10 E D C B A (Cont. next page) W–G 20 C B–W B–W B B–R 9 E ngine C ontrol B F E D C B A R–G 2 PRIUS (Cont’ d) M OVERALL ELECTRICAL WIRING DIAGRAM 2 PRIUS (Cont’ d) E ngine C ontrol 16 R–G B–R F A B–W H B B–R B–W 11 ID2 8 ID1 10 ID2 IG 1 D L P Y BR O IND 5 22 D NEO ACT 23 C 16 C TAM 21 C ESTP 10 C GO SPHV 18 C 19 C HTE– HTE+ 28 C ETH+ 27 C ENGINE CONTROL MODULE ETH– 8 ID2 KNK1 G2 NE– NE+ 24 B E1 16 B E01 E02 17 B 21 A 31 A E03 3 A ME01 9 A B A 9 ID1 L–B (*1) A A A A 8 C BR 7 B 4 BR A W–B W–B W–B W–B W–B BR E (*1) C7 CENTER CLUSTER SW (*1) (*1) D 6 R3 B , R4 C A B RADIO AND PLAYER A B LG–B A B (*1) Engine block EB EA Engine block Left kick panel IF To Unlock Warning SW<9–2><15–3> A A J27 A , J28 B JUNCTION CONNECTOR To Door Courtesy SW Front LH<10–2> A A E B BR A A BR J8 A , J9 B 2 JUNCTION CONNECTOR 1 BR G C6 CRANKSHAFT POSITION SENSOR 2 G C1 CAMSHAFT POSITION SENSOR 1 (*1) R B K1 KNOCK SENSOR 1 J20 JUNCTION CONNECTOR W–B W–B W–B W–B BR (*1) 1 EA1 B LG–B R G (*1) B (*1) (*1) A L–B 10 A 7 W–B 28 A KSW 6 L–B 3 D J10 JUNCTION CONNECTOR SPD CTY R–W 5 D FAN HEVC W–B 4 A 12 LG–B G E 7 A , E 8 B , E 9 C , E10 D 8 +B T4 TRANSPONDER KEY COMPUTER GND G R–Y V–W LG 2001 PRIUS (EWD414U) 9 IA2 B–W 3 J20 JUNCTION CONNECTOR R–G R–G B–R B–W From Hybrid Vehicle Control ECU<1–9> See Air Conditioning System<24–6> To Combination Meter <23–2> From FAN NO. 1 and FAN NO. 2 Relay <22–3> A A 2 * 1 : Shielded To Hybrid Vehicle Control ECU<1–20> C 15 14 J27 A , J28 B B 13 R–G JUNCTION CONNECTOR R–G A H y brid V ehic le Immobiliser S ys te m ID J11 JUNCTION CONNECTOR Cowl side panel LH M 3 PRIUS R–B B W B 15A DOME 100A DC/DC 15A STOP 2001 PRIUS (EWD414U) R R F11 B , F12 C , F13 D B–G LIGHT CONTROL SW FUSIBLE LINK BLOCK NO. 1 120A MAIN F18 FUSIBLE LINK BLOCK NO. 2 DIMMER SW W–B IG R–G 6 2B 7 2I Right kick panel 7 2A 10 2A 14 BR IH 21 4 2A 2 2G R6 STOP LIGHT LH [REAR COMB. LIGHT LH] Left side of rear pillar B A C B 5 2 A B C A W–B BI C B 2 1 A B J14 A , J15 B To Hybrid Vehicle Control ECU<1–6> G–W W–B Back panel center J32 A , J33 B BK 5 2 To Shift Lock ECU<13–3> G–W JUNCTION CONNECTOR JUNCTION CONNECTOR To Brake ECU <19–12> JUNCTION CONNECTOR J30 A , J31 B D B D B C A E A E A G–W S3 STOP LIGHT SW 4 W–B Cowl side panel RH A F A L J17 JUNCTION CONNECTOR D B F A R–G BATTERY R–W 16 17 17 L FLASH 7 JUNCTION CONNECTOR HF HU HL 8 1 9 IB1 W–B C13 COMBINATION SW EL E A 2 H2 HEADLIGHT RH E A 1 W–B HEAD T R–G 3 IA1 R–G H J4 A , J5 B 13 JUNCTION CONNECTOR R–Y R–G 5 ID2 R–Y 7 IA1 J4 A , J5 B H E A E B R–G 17 B9 BODY ECU R–G R–Y 3 7 1F 10A HEAD (RH) H15 HIGH MOUNTED STOP LIGHT HIGH 2 R–W HRLY D B F A 1 H1 HEADLIGHT LH 10A HEAD (LH) 2 S top L ight G–W LOW R–W G–W TAIL OFF J20 JUNCTION CONNECTOR G–W 1 R–W F A 2 3 6 1F R–Y 1 D 1 C R–W 4 SHORT PIN R–B G–W 3 ID2 E HEAD RELAY 1 L–Y E E 6 IA2 2 1 3 G–W 1 B 2 1B 8 1F 3 R–W 1 2H 7 1J L–Y 9 2K SHORT PIN 4 2 H eadlight (w /o D aytime R unning L ight) G–W 1 1B 1 2 1 P ow er S ource M OVERALL ELECTRICAL WIRING DIAGRAM R7 STOP LIGHT RH [REAR COMB. LIGHT RH] C10 COMBINATION METER L HEAD HIGH BEAM R–L JUNCTION CONNECTOR J12 A , J13 B 4 PRIUS H eadligh t (w / D ay time R unning Light) P ow er S ourc e 1 3 2 4 R–G W–G 2 AM1 IG1 4 H B B–Y L PKB L–O 7 DIMMER SW T HF HU HL EL OFF TAIL HEAD LO HIGH FLASH 13 8 16 BR A W–B R–G C13 COMBINATION SW W–R Cowl side panel LH 6 2B 11 +B J11 JUNCTION CONNECTOR ID R–Y R–G 3 HI LIGHT CONTROL SW 5 ID2 W–R A 12 R W–B IE W–B 7 2A 8 H R–G W–B R–B R–G R–G R–B A J1 JUNCTION CONNECTOR Cowl side panel LH E R–G A BATTERY J20 JUNCTION CONNECTOR 2 E R–G 3 D5 DIODE(Daytime Running Light) 1 E R–W R–B 2 R–G 1 To Parking Brake SW <19–8> E 2 W–B R–B 16 IA2 9 IA1 R–L 7 R–G L DRL H 6 DIM H–LP IG D3 DAYTIME RUNNING LIGHT RELAY R–G R–G G–R H2 HEADLIGHT RH 3 4 IND R–G R–W R–Y 2 CHG– 1 A 6 IA2 R–B R H1 HEADLIGHT LH 120A MAIN F18 FUSIBLE LINK BLOCK NO. 2 1 H 5 17 B 3 ID2 E 1 R–G HRLY 2 B 3 R–W Y–B 9 R 5 1E RDY C 7 2I 9 A R–W 3 B8 A , B9 B W–B 2 W–B 2 1E DRL RELAY 10A HEAD HI (RH) 10A HEAD HI (LH) 10A HEAD LO (RH) 10A HEAD LO (LH) B–G F11 B , F12 C , F13 D FUSIBLE LINK BLOCK NO. 1 100A DC/DC 1 D 7 1F 3 1 5 17 IA2 7 ID2 BODY ECU 3 3 6 1F 10 2A Y–B 3 8 2K 2 B 1 C L A R–G 3 21 L R–L 1 1B 2 L R–G DIM RELAY 17 C J20 JUNCTION CONNECTOR 5 R–G 1 2 4 8 ID1 R–L 7. 5A DRL 1 3 B 1 B 3 IG1 RELAY 30A HEAD 1 W 2001 PRIUS (EWD414U) 15A DOME 2 1 2 1B SHORT PIN HEAD HEAD RELAY 2 HIGH BEAM 1 R–G 3 5 10A GAUGE 4 10 2K C10 COMBINATION METER 11 1J 5A AM1 1 3 1E 14 5 2C 1 2H L R–L 8 1F 6 2D 3 2B 7. 5A ECU–B 7 1J R L R–G L–Y I15 IGNITION SW R–G 2 2G W W–G B–Y ST1 J27 A , J28 B ACC 4 2A JUNCTION CONNECTOR L F A J17 JUNCTION CONNECTOR Cowl side panel RH IG Right kick panel IH M 5 PRIUS W W 10A TURN–HAZ B 2001 PRIUS (EWD414U) 100A DC/DC B–G Cowl side panel LH Cowl side panel RH W–B W–B W–B 120A MAIN IG J18 JUNCTION CONNECTOR J17 JUNCTION CONNECTOR W–B IE A W–B ID A W–B BI JUNCTION CONNECTOR J32 A , J33 B Left side of rear pillar W–B BK 5 3 3 2M Back panel center R7 REAR TURN SIGNAL LIGHT RH [REAR COMB. LIGHT RH] W–B Cowl side panel LH J11 JUNCTION CONNECTOR B A C B 5 3 5 2M 1 2A 18 6 2B 7 2A 14 IH BR Cowl side panel LH J1 JUNCTION CONNECTOR W–B G–Y 8 2K W–B ID J11 JUNCTION CONNECTOR A J4 JUNCTION CONNECTOR 2 1 J7 JUNCTION CONNECTOR A F8 FRONT TURN SIGNAL LIGHT RH A A 2 1 F7 FRONT TURN SIGNAL LIGHT LH G–B W–B A A JUNCTION CONNECTOR J12 A , J13 B B A G–Y 3 2F W–B A 4 2K R6 REAR TURN SIGNAL LIGHT LH [REAR COMB. LIGHT LH] BATTERY A A 11 IA1 G–Y F18 FUSIBLE LINK BLOCK NO. 2 B W–B A B B B A 2 2 2A 19 RH G–Y 1 FUSIBLE LINK BLOCK NO. 1 2 7 J24 JUNCTION CONNECTOR G–B 1 D W–G F11 B , F12 C , F13 D LH 10A GAUGE RH 3 6 LR LL 3 G–Y C13 TURN SIGNAL SW [COMB. SW] TURN 1 5 8 G–Y 1 B 8 2K 5A AM1 IG1 RELAY W 3 5 J20 JUNCTION CONNECTOR R–L R–L EL 1 G–R IG HAZ T5 TURN SIGNAL FLASHER RELAY ER E G–B B 4 G–B 8 2D W–B 12 2J A W–B 1 C B–Y C H7 HAZARD SW [HAZARD WARNING SW] G–R 4 ID1 LH L 2 1B W–G 6 IA1 A E A D B 4 C10 TURN SIGNAL INDICATOR LIGHT [COMB. METER] L 2 1 W 10 2K R–L 1 2H W 3 2B W–B J22 A , J23 B 6 2D C 4 3 3 L 6 1J ST1 IG1 4 ACC 2 T urn S ignal and H az ard W arning Light JUNCTION CONNECTOR I15 IGNITION SW 2 AM1 1 P ow er S ource Right kick panel M OVERALL ELECTRICAL WIRING DIAGRAM G–Y W–B L–B 6 PRIUS P ow er S ource B ac k– U p Light 1 3 2 4 R–B R–B ACC D A D A B A JUNCTION CONNECTOR IG1 4 ST1 B B 3 2B R–L 6 2D 3 2C 1 2H 1 2 W–G R–B 1 R–B 10A GAUGE 5A AM1 B5 BACK–UP LIGHT RELAY 5 To Navigation ECU <14–6> 3 R–B R–L W W–G B–Y I15 IGNITION SW 5 IJ1 J27 A , J28 B 2 AM1 JUNCTION CONNECTOR W–G 9 IF1 5 IH E 9 C , E10 D W–B 14 D MPX1 J32 A , J33 B 13 D MPX2 5 W–B 18 C HTE– B A JUNCTION CONNECTOR C B GR–L 19 C HTE+ 4 W–B BR MPD2 11 R7 BACK–UP LIGHT RH [REAR COMB. LIGHT RH] 5 G1 GATEWAY ECU 1 4 6 2B 4 R–B 4 7 2A R6 BACK–UP LIGHT LH [REAR COMB. LIGHT LH] MP2+ GR–B Cowl side panel LH MPX+ GR ID 16 BR J11 JUNCTION CONNECTOR MPX– W–B W–B W–B A BATTERY HTE– 29 D MPD1 Y E P1 PARK/NEUTRAL POSITION SW J22 JUNCTION CONNECTOR 120A MAIN F18 FUSIBLE LINK BLOCK NO. 2 HTE+ 19 D B–R W–B B–G 4 1 E 11 MPX+ RL 14 E L A 1 D 15 A7 A/C AMPLIFIER A B8 BODY ECU J24 JUNCTION CONNECTOR 100A DC/DC F11 B , F13 D FUSIBLE LINK BLOCK NO. 1 R–B H13 E , H14 D HYBRID VEHICLE CONTROL ECU B B GR W–B 1 B 3 B GR–B W–B 2 B B A J30 A , J31 B 8 2D R–B 8 2K 14 A C10 A , C11 B 1 B 3 COMBINATION METER 2 W 2001 PRIUS (EWD414U) L IG1 RELAY Right kick panel BI Left side of rear pillar BK Back panel center ENGINE CONTROL MODULE M 1 2H W OFF 100A DC/DC 2001 PRIUS (EWD414U) LG–R LIGHT CONTROL SW B–G 120A MAIN Cowl side panel LH W–B IG W–B W–B IE A W–B Cowl side panel RH F5 FRONT SIDE MARKER LIGHT LH J1 JUNCTION CONNECTOR Left side of rear pillar L2 LICENSE PLATE LIGHT LH B A C B 2 1 W–B A 1 2 A A W–B BI 1 A A W–B C B 5 6 A A J32 A , J33 B Back panel center JUNCTION CONNECTOR W–B BK 2 1 A A L3 LICENSE PLATE LIGHT RH J17 JUNCTION CONNECTOR F4 FRONT PARKING LIGHT RH J7 JUNCTION CONNECTOR W–B 2 1 A A G A A G 16 G W–B JUNCTION CONNECTOR G G HEAD EL 2 1 F B D A J4 A , J5 B F B D A 5 2L W–B C13 COMBINATION SW H 1 2 10 IA1 5 2F J32 A , J33 B JUNCTION CONNECTOR G T 7 2J 7. 5A TAIL G TAIL 14 B9 BODY ECU TAIL RELAY 3 4 5 1 A A A B G BATTERY F18 FUSIBLE LINK BLOCK NO. 2 LG–R 6 ID2 18 T 3 5 2 Taillight G 1 LG TRLY 11 2 ID2 LG 1 D F11 B , F13 D 6 2K 2 1 G 1 B 1 P ow er S ource G FUSIBLE LINK BLOCK NO. 1 7 PRIUS 6 M OVERALL ELECTRICAL WIRING DIAGRAM G W–B R7 TAILLIGHT RH [REAR COMB. LIGHT RH] G R6 TAILLIGHT LH [REAR COMB. LIGHT LH] W–B F6 FRONT SIDE MARKER LIGHT RH F3 FRONT PARKING LIGHT LH W–B W–B 8 PRIUS P ow er S ource Illumination 1 3 2 4 L 4 2A LG LG TAIL RELAY 5A PANEL H A H A LG 5 LG 1 H A H A J27 A , J28 B 2 1 2H 2 2G 3 6 2K JUNCTION CONNECTOR F B 1 2D F B F B F B L L–Y LG C10 A , C11 B 7 1J COMBINATION METER 5 10 6 B 5 W–B E C C E C W–B A 7 2A 8 2D 6 2B 8 2K D B JUNCTION CONNECTOR A BR BR W–B Right kick panel IH W–B E A Left kick panel A L W–B W–L W–L W–L 120A MAIN B J21 JUNCTION CONNECTOR C J24 JUNCTION CONNECTOR W–L J21 JUNCTION CONNECTOR C J22 A , J23 B IF W–L LG–B A J21 JUNCTION CONNECTOR BATTERY 7 B 14 A L W–B J21 JUNCTION CONNECTOR B–G B 3 A W–L B W–L 6 A 1 F18 FUSIBLE LINK BLOCK NO. 2 4 W–L W–L W–L W–L BR 1 D L1 LIGHT CONTROL RHEOSTAT 5 A LG LG C7 CENTER CLUSTER SW 2 10 B R2 A , R3 B 6 5 RADIO AND PLAYER 8 LG LG 1 H7 HAZARD WARNING SW 2 W–L W–L 100A DC/DC F11 B , F12 C , F13 D LG 1 M7 MULTI DISPLAY C9 CIGARETTE LIGHTER ILLUMINATION 2 1 B FUSIBLE LINK BLOCK NO. 1 LG LG B 1 C A22 ASHTRAY ILLUMINATION See Taillight System<7–1> W 15A DOME 2001 PRIUS (EWD414U) 2 1B 21 A J11 JUNCTION CONNECTOR Cowl side panel LH ID M L L–Y W B 15A DOME 2001 PRIUS (EWD414U) 100A DC/DC B A FUSIBLE LINK BLOCK NO. 1 F11 B , F12 C , F13 D B–G W–B 120A MAIN G–O A B W–B A A A B A A W–B E A D B W–B JUNCTION CONNECTOR J24 A , J25 B W–B W–B W–B B21 BUCKLE SW RH AND SEAT BELT WARNING OCCUPANT DETECTION SENSOR 1 W–B U1 UNLOCK WARNING SW 2 P–L L–B W–B 11 IJ1 B20 BUCKLE SW LH 10 IJ1 1 1 2 2 B JUNCTION CONNECTOR J22 A , J23 B A G–O ID A B A See Interior Light System <10–2> J27 A , J28 B 3 A A G–O JUNCTION CONNECTOR PKBL 3 B 9 IJ1 To Airbag Sensor Assembly <21–3> 2 5 B MPX+ DBKL 15 A 3 B COMBINATION METER C10 A , C11 B A7 A/C AMPLIFIER 22 A Right kick panel BUZZER 14 A 21 A 6 2B 7 2A IH BR Cowl side panel LH J11 JUNCTION CONNECTOR LG L–B F B 1 2K MPX– 16 A 11 MPX+ MP2+ 4 4 MPD1 MPD2 11 SEAT BELT (Front Passenger’ s Seat) L BATTERY BODY ECU From Transponder Key Computer <2–16> 10A GAUGE 2 ID2 9 2C 7. 5A TAIL P–L F18 FUSIBLE LINK BLOCK NO. 2 6 2K B8 A , B9 B 3 DCTY T J29 JUNCTION CONNECTOR 1 IG1 RELAY 8 2D KSW H 8 IJ1 G–O 1 D 5A AM1 8 2K TAIL RELAY 12 See Headlight System<3–1><4–3> 17 B 18 B See Taillight System<7–1> HRLY 2 B GR B GR–B TRLY E 11 B 1 B R–G 9 B G–O IG 15 13 MPX2 MPX1 From Airbag Sensor Assembly<21–2> TAIL 17 E10 ENGINE CONTROL MODULE GR–L GR–B 3 5 3 5 7. 5A ECU–B 2 1 F J27 JUNCTION CONNECTOR 14 G–O GR 2 1 1 2H 5 2A F 4 S eat B elt W arning L 1 C B–Y 3 2B W–G 6 2D W GR–B 2 1B ST1 IG1 4 5 2C L R–G 3 Light A uto T urn O ff G1 GATEWAY ECU 7 1J I15 IGNITION SW 2 AM1 ACC 2 K ey R eminder and L ight R eminder B uz zer GR–L 2 2G 4 2A W–G 1 P ow er S ource L 1 B 9 PRIUS M OVERALL ELECTRICAL WIRING DIAGRAM SEAT BELT (Driver’ s Seat) L–B W–B LG W–B W–B 10 PRIUS P ow er S ource Interior Light 1 3 2 4 B B L GR–B 2 1B GR–B W–G ACC 2 AM1 IG1 4 15A DOME 4 5 2C 5 2A MPD2 7 1J 11 4 2A 3 2N 3 B 2 B 22 A 21 A 12 A 6 2L D B D B L–Y 1 P5 PERSONAL LIGHT 1 R–W J30 A , J31 B JUNCTION CONNECTOR L5 LUGGAGE COMPARTMENT LIGHT 2 E B D A J30 A , J31 B E A L–Y DOOR BR 1 R–W D A 1 W–B R–W 2 R–W 1 B L6 LUGGAGE COMPARTMENT LIGHT SW B J33 JUNCTION CONNECTOR BR W–B D9 DOOR COURTESY SW REAR RH 1 R 1 I16 INTERIOR LIGHT ON OFF R–B R–W R 2 6 2B 4 IF1 D8 DOOR COURTESY SW REAR LH R–G ID D4 DIODE (Door Courtesy) 1 R–G Cowl side panel LH 1 E A 2 7 2A 3 IB1 R–Y J11 JUNCTION CONNECTOR BATTERY 3 L–Y R–B D6 DOOR COURTESY SW FRONT LH R–W R–W W–B A D7 DOOR COURTESY SW FRONT RH 120A MAIN F18 FUSIBLE LINK BLOCK NO. 2 A R–W A J12 A , J13 B J16 JUNCTION CONNECTOR 1 D A 14 A 1 2N R–W B–G A D A F B R–W 1 D F B JUNCTION CONNECTOR R–W FUSIBLE LINK BLOCK NO. 1 From Transponder Key Computer<2–16> 100A DC/DC 13 ID2 F11 B , F12 C , F13 D 3 2K LP 7 JUNCTION CONNECTOR 1 2K R–W LCTY 14 A 6 R–W 1 B RCTY 3 L R–W W–B W–B W 1 C 1 B L–Y 8 2D 8 2K DCTY C10 A , C11 B COMBINATION METER MPX– BODY ECU PCTY 2 2G L–Y L GR–B 13 16 A MPX+ MPX+ 11 DOOR 15 A B B8 A , B9 B MP2+ GR MPX2 GR 9 B IG MPX1 GR–B R–G 15 3 E B 2001 PRIUS (EWD414U) IG1 RELAY 14 GR–L E10 ENGINE CONTROL MODULE F 5 2 J27 JUNCTION CONNECTOR 7. 5A ECU–B 10A GAUGE 5A AM1 1 F 4 L–Y I15 IGNITION SW MPD1 A7 A/C AMPLIFIER 1 2H G1 GATEWAY ECU 3 2B L 6 2D W W–G B–Y ST1 R–G 7 IC1 R–Y From Power Window Master SW<18–2> Right kick panel IH Left side of rear pillar BI M W LG L 100A DC/DC 2001 PRIUS (EWD414U) B–G HR BR–R A A A 6 M+ W–B 120A MAIN M R10 REMOTE CONTROL MIRROR LH M M 5 3 R11 REMOTE CONTROL MIRROR RH M 1 L 3 LG 5 BR–R 1 W W–B Cowl side panel LH R–G 10 IN1 BR–R 8 IN1 2 W 9 IN1 L R–G 10 IG1 5 HL R–G ID VR LEFT/UP BR–R 8 IG1 3 MH A A A B 7 E R5 REMOTE CONTROL MIRROR SW BR–R 9 IG1 4 DOWN J11 JUNCTION CONNECTOR UP VL MV LEFT A 8 2D 10A ACC 8 B BR–R BATTERY ACC RELAY 15A CIG 2 2D GR–R F18 FUSIBLE LINK BLOCK NO. 2 3 5 5A AM1 5 2D J27 JUNCTION CONNECTOR RIGHT/DOWN 1 2 1 W–G 1 2H W 3 2B GR RIGHT 8 2K 8 2C C C A A 4 1 2 C igarette L ighter W–B 1 D P–L GR–R SELECT SW FUSIBLE LINK BLOCK NO. 1 ST1 IG1 ACC 3 3 GR–R I15 IGNITION SW 2 AM1 2 R emote C o ntrol M irror OPERATION SW 1 B W–G 1 P ow er S ource GR F11 B , F13 D 11 PRIUS M OVERALL ELECTRICAL WIRING DIAGRAM C8 CIGARETTE LIGHTER W–B JUNCTION CONNECTOR J24 A , J25 B W–B W–B J26 JUNCTION CONNECTOR W–B 12 PRIUS P ow er S ource H orn W iper and W as her 1 3 2 4 L C12 FRONT WIPER AND WASHER SW[COMB. SW] 10 IH1 ACC W–G 2 AM1 IG1 4 L 1 2H 2 2N 6 2I +S 3 2G W1 M WASHER MOTOR 1 L–Y 11 +B 17 WIPER RELAY +2 E 2 8 EW +1 WF +S 7 16 L–W L–B L–R W–B L L–Y IG1 RELAY 16 IA1 17 IA1 15 IA1 3 L–W L–B L–R 9 1F B–W W–B B–R L B W W–B 8 IA2 3 5 1 2 +2 +1 +S +B 1 H4 HORN B–R A J20 JUNCTION CONNECTOR D D M J18 JUNCTION CONNECTOR D A B–R B–G F11 B , F12 C , F13 D 100A DC/DC FUSIBLE LINK BLOCK NO. 1 2001 PRIUS (EWD414U) 1 D B1 HI WF 5 2 1 C INT2 WASHER 8 2K 1 B INT1 LOW 30A WIPER 15A WASHER 5A AM1 1 3 2 1J L 2 IA1 HORN RELAY 2 +1 2 3 2B 5 10A HORN L 6 2D W W–G B–Y I15 IGNITION SW 1 +2 INT L ST1 2 1B +B OFF B–Y 1 E W–B B–R F9 FRONT WIPER MOTOR W–B C14 HORN SW [COMB. SW] J7 JUNCTION CONNECTOR A A W–B 6 4 W–B To Body ECU <17–2> 120A MAIN F18 FUSIBLE LINK BLOCK NO. 2 A A J11 JUNCTION CONNECTOR BATTERY Cowl side panel LH ID A J17 JUNCTION CONNECTOR IG Cowl side panel RH J1 JUNCTION CONNECTOR IE Cowl side panel LH M W 100A DC/DC 2001 PRIUS (EWD414U) A A 10A ACC E B–G A A A B 5 STP 6 1 ID2 W–B W–B 120A MAIN JUNCTION CONNECTOR J24 A , J25 B W–B IG P2 P P1 E A D B E E 3 4 4 KLS+ B JUNCTION CONNECTOR J22 A , J23 B W–B J21 JUNCTION CONNECTOR D B 2 SHIFT LOCK CONTROL SW FREE SHIFT LOCK SOLENOID 1 1 Y LOCK U1 KEY INTERLOCK SOLENOID [UNLOCK WARNING SW] SLS– 2 L–R 3 B 4 11 IJ1 1 3 2 1 12 IJ1 B20 TENSION REDUCER LH[BUCKLE SW LH] T6 TENSION REDUCER SOLENOID E lec tric T ension R educ er R J21 JUNCTION CONNECTOR J14 JUNCTION CONNECTOR SLS+ 3 D D 1 S2 SHIFT LOCK ECU J26 JUNCTION CONNECTOR 5 ID1 ACC B B C B J27 A , J28 B JUNCTION CONNECTOR D W–B W–B Cowl side panel LH J11 JUNCTION CONNECTOR ACC RELAY C A D W–B ID A 8 2D 3 5 2 2D G–W L BATTERY IG1 RELAY 2 1 8 2C GR–R F18 FUSIBLE LINK BLOCK NO. 2 3 5 5A ECU–IG 2 2I G–W W–B 1 W–G 5A AM1 4 2C B–Y GR–R 2 1 W 1 2H B–Y 3 2B P–L B–Y 8 2K 6 2D GR–R G 1 D P–L B–Y From Stop Light SW<3–4> B–Y FUSIBLE LINK BLOCK NO. 1 ST1 IG1 4 ACC 3 3 GR–R I15 IGNITION SW 2 AM1 2 S hift L ock B–Y 1 B W–G 1 P ow er S ource B–Y F11 B , F13 D 13 PRIUS M OVERALL ELECTRICAL WIRING DIAGRAM W–B W–B W–B W–B MEMO 2001 PRIUS (EWD414U) 14 PRIUS L–Y 2 2G 4 2D L–Y W 15A DOME B 2001 PRIUS (EWD414U) 100A DC/DC 1 2 1 2 P (*1) B–G Left kick panel V (*1) W–B 120A MAIN +B 2 4 GND C7 CENTER CLUSTER SW 9 EJCT 1 ACC GR BR W–B IF LG R9 REAR SPEAKER RH B R8 REAR SPEAKER LH Y F15 FRONT DOOR SPEAKER RH 2 P–B F14 FRONT DOOR SPEAKER LH 1 L–R ID 2 TX– 8 F G Cowl side panel LH J11 JUNCTION CONNECTOR A 1 F TX+ 7 C C TX+ 10 C TX– 9 C FL+ 2 B R BATTERY F18 FUSIBLE LINK BLOCK NO. 2 6 IF1 5 IF1 BR R 8 IF1 P (*1) W 7 IF1 V (*1) 4 IN1 LG L 3 IN1 L 4 IG1 GND 8 C BU+B 5 C FL– 6 B 8 IJ2 9 IJ2 G 3 IG1 4 IJ1 BR ACC+B EJECT 12 C 11 C GR–R GR–R R 1 RR– 3 A RR+ 1 A RL– 6 A FR– 5 B RADIO AND PLAYER RL+ 2 A B FR+ 1 B 5A ECU–IG Y FL– 6 B 7. 5A ECU–B R FL+ 2 B GR–R W GND 7 B ACC RELAY 1 D F11 B , F12 C , F13 D 3 B ACC+B R2 A , R3 B , R4 C GR–R J26 JUNCTION CONNECTOR C B GR–R FUSIBLE LINK BLOCK NO. 1 L–Y BU+B GR–R 4 B B B C B C A 4 R G F P(*2) V(*2) GR–R GR–R GR–R L–Y L–Y B–Y R–G C * 1 : w/o Navigation System * 2 : w/ Navigation System V (*2) 1 B 5A AM1 8 2K 10A ACC 5 J24 A , J25 B 2 JUNCTION CONNECTOR L–Y C B C A J27 A , J28 B 3 C B B A JUNCTION CONNECTOR 2 3 L–Y B A L–Y IG1 RELAY 1 L–Y B A GR–R P (*2) 1 C B–Y 8 2C 2 2D 3 GR–R 2 1B W–G 5 W 1 B–Y 5 2C R–G 2 2I P–L 1 2H GR–R 6 2D 3 2B P–L 2 R adio and P layer GR–R 7 1J ST1 IG1 4 ACC 3 I15 IGNITION SW W–G 2 AM1 1 P ow er S ource K J I H G F E D C B A (Cont. next page) M OVERALL ELECTRICAL WIRING DIAGRAM J26 JUNCTION CONNECTOR 14 PRIUS (Cont’ d) N av igation S ys tem A B E B–Y L–Y D M5 A , M6 B , M7 C L–Y MULTI DISPLAY D GR–R GR–R B 3 B VR 1 B TC 14 A B–Y 1 B VR 6 B VG 17 A GND 8 2D MPX2 13 GR To Combination Meter <23–3> R–B From Back–Up Light Relay<6–4> BR V–W Left kick panel IF A W–B V–W NAVIGATION ECU 3 IJ1 MPX1 W–B 8 2K 21 IJ1 J11 JUNCTION CONNECTOR ID Cowl side panel LH 3 MPX– MPX+ 16 B8 BODY ECU REV 14 A C11 COMBINATION METER N2 A , N3 B BR BR SPD 5 A 14 GR D B MPX+ 11 GR–L 3 B B 4 MP2+ E10 ENGINE CONTROL MODULE 8 B SYNC MPD2 11 GR–B 7 B G E A7 A/C AMPLIFIER 2 B R J22 A , J23 B 10 B TX1– E A JUNCTION CONNECTOR W–B 5 B TX1+ E W–B A BATT 4 W–B A W–B J21 JUNCTION CONNECTOR A 8 IG MPD1 7 W–B J24 JUNCTION CONNECTOR (SHIELDED) Y G B R W (SHIELDED) G (*2) 2 A AUO+ G R (*2) 9 A +B R GR–R K R G V(*2) 11 A AUO– P(*2) 1 A 10 A 18 A AUI+ AUI– ACC L–Y J 6 IJ2 2 CG 14 G (*2) R (*2) 7 IJ2 3 IG1 R–G 9 ACC G1 GATEWAY ECU GND 4 IG1 H B B–Y 5 GTX– GTX+ F A J21 JUNCTION CONNECTOR GR–R 12 R 20 IJ1 D D G 19 IJ1 D B–Y To Parking Brake SW <19–8> 18 IJ1 (SHIELDED) 15 IJ1 Y 17 IJ1 G 16 IJ1 B 22 IJ1 R 7 IJ1 W P (*2) V (*2) 6 IJ1 G R F14 FRONT DOOR SPEAKER LH 2 1 P(*2) (SHIELDED) I V(*2) 5 ID1 To Combination Meter <23–3> R–Y To Data Link Connector 3<2–5> 7 ID1 L–Y 2001 PRIUS (EWD414U) H TX3– TX3+ IG 11 A 4 A 2 C R SPD 5 A G GND1 6 C P–B Y G B R W (SHIELDED) 1 IJ1 PKB 13 A J27 A , J28 B SYNC 8 B V–W G 7 B BR R 2 B R–Y VG 6 B BR TX1– 10 B G R GR–R L–Y L–Y TX1+ 5 B G +B1 ACC TX+ TX– 1 C 4 C 3 A 10 A GR–R R F G 8 R–G D 7 6 JUNCTION J14 CONNECTOR JUNCTION CONNECTOR B–Y B–Y B–Y C 5 R–G G atew ay S y stem * 2 : w/ Navigation System 2 MPX– MPX+ 15 GR–B M W J11 JUNCTION CONNECTOR Cowl side panel LH 1 B E 9 2C 12 D B B A J27 A , J28 B L–B L–Y F11 B , F12 C 2001 PRIUS (EWD414U) A A From Transponder Key Computer<2–16> W–B B A B8 A , B9 B BODY ECU KSW L–B W–B W–B FUSIBLE LINK BLOCK NO. 1 F18 FUSIBLE LINK BLOCK NO. 2 100A DC/DC B–G 120A MAIN A A W–B 1 2K 3 RX 6 A MPX1 18 5 IG1 5 16 CPUB DCTY DCTY 6 15 KUL 2 IG1 3 5 6 KL P9 POWER WINDOW MASTER SW UNLOCK JUNCTION CONNECTOR J24 A , J25 B U1 UNLOCK WARNING SW 3 2K PCTY 12 A W–B A B 1 2 6 2L 6 RCTY L–B W–B ID A 15 IG LSWD ACTD 10 B 1 M 2 5 IC1 7 IG1 D13 DOOR LOCK MOTOR, DOOR KEY LOCK AND UNLOCK SW AND DOOR DETECTION SW FRONT LH 4 10 W BATTERY 8 B 9 B B G–Y 1 IG1 W–B 5 2C R 1 B G 1 D L–Y C B 8 2D 1 2H 4 R 1 C 3 5 5A AM1 B A 2 1 3 2B Y 8 2K IG1 RELAY 6 2D J27 JUNCTION CONNECTOR 3 D oor Loc k C ontrol A (Cont. next page) G 1 B 4 2D B–Y F F 2 L–B 2 1B 15A DOME L–Y 2 2G ST1 W–G 7 1J W–G IG1 4 ACC W I15 IGNITION SW 2 AM1 1 P ow er S ource R–G J24 A , J25 B R–G Y JUNCTION CONNECTOR 15 PRIUS M OVERALL ELECTRICAL WIRING DIAGRAM LOCK W–B See Power Window System<18–2> L–Y See Interior Light System <10–2><10–3> JUNCTION CONNECTOR W–B 10A GAUGE 30A DOOR 7. 5A ECU–B W–B L–Y , F13 D 15 PRIUS (Cont’ d) D oor L ock C ontrol 5 7 6 8 B8 A , B9 B BODY ECU UL2 L2 16 B LSWP 7 B 17 A 4 2I 1 2J 8 2L 9 2L W–L R G W–L B B 1 IF1 2 BA1 6 BA1 W–B 1 BA1 D10 DOOR LOCK CONTROL SW FRONT RH 3 W–B 3 UNLOCK 1 BB1 5 LOCK D11 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR LH 6 W–B D12 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR RH W–B M 4 R–B 1 6 IN1 G–B 2 M 2 W–L 1 1 IN1 7 BA1 R G W–L 3 4 1 W–L W–L W–B D14 DOOR LOCK MOTOR, DOOR KEY LOCK AND UNLOCK SW AND DOOR UNLOCK DETECTION SW FRONT RH 7 BB1 R 5 M 7 IQ1 B J33 JUNCTION CONNECTOR B 2 IQ1 W–B W–B W–B A B W–B W–B J18 A , J19 B W–B A B 6 6 BB1 G LOCK UNLOCK 4 2 BB1 R 3 2 R G R 2 6 IQ1 G W G L–B 1 5 IQ1 2 IF1 L4 LUGGAGE COMPARTMENT DOOR UNLOCK SW A B B A L–B B B G 2 IN1 LUG 5 A J22 A , J23 B A B B A JUNCTION CONNECTOR JUNCTION CONNECTOR W G L–B 2001 PRIUS (EWD414U) B A 12 ID2 12 IN1 UL1 15 B J14 A , J15 B C A B B 11 IN1 L1 14 B G–B R G G C A LSR 18 A L–B 16 R–B ACT– 9 W–L A ACT+ JUNCTION CONNECTOR A A A W–B W–B A IG J17 JUNCTION CONNECTOR Cowl side panel RH BI Left side of rear pillar Right side of rear pillar BJ M 16 PRIUS W 2001 PRIUS (EWD414U) R–G L–Y 2 J23 JUNCTION CONNECTOR 10A GAUGE 7. 5A ECU–B 100A DC/DC FUSIBLE LINK BLOCK NO. 1 F11 B , F12 C , F13 D B–G E E 1 E RDA A A A A KSW A A A B 1 2 B B 9 2C 12 JUNCTION CONNECTOR J24 A , J25 B U1 UNLOCK WARNING SW J27 JUNCTION CONNECTOR LUG 5 A W–B 120A MAIN BJ B B 1 2 2 IF1 W–B W–B L–Y Cowl side panel LH 3 B–R PRG B–R W5 WIRELESS DOOR CONTROL RECEIVER R–G L +B F L ID W–B J11 JUNCTION CONNECTOR R–G 5 F F 5 2C RDA 8 A W–B BATTERY A W–B PRG 7 A B8 A , B9 B BODY ECU W–B F18 FUSIBLE LINK BLOCK NO. 2 8 2D 9 B S B 8 W–B 1 IG1 8 2K IG1 RELAY 1 B E IG 15 6 2L 6 RCTY Right side of rear pillar J33 JUNCTION CONNECTOR L4 LUGGAGE COMPARTMENT DOOR UNLOCK SW 1 C B JUNCTION CONNECTOR J24 A , J25 B 3 5 1 2H L–B 1 D B 1 C L–Y B A 2 1 3 2B 5A AM1 4 2D 2 2G 6 2D 3 W ireless D oor L ock C ontrol L–B 1 B 15A DOME L–Y B–Y 2 30A DOOR 2 1B ST1 W–G L–B 7 1J W–G IG1 4 ACC W I15 IGNITION SW 2 AM1 1 P ow er S ourc e 3 2K 4 12 A PCTY L–Y W–B 1 2K 3 DCTY B A (Cont. next page) M OVERALL ELECTRICAL WIRING DIAGRAM See Interior Light System <10–2><10–3> W–B W–B W–B W–B R–G W–B J27 JUNCTION CONNECTOR 16 PRIUS (Cont’ d) W ireless D oor Loc k C ontrol 5 7 6 8 B8 A , B9 B BODY ECU RX ACTD 6 A UL2 10 B L2 16 B LSWP 7 B 17 A ACT+ ACT– 9 16 4 2I 1 2J LSR L1 18 A UL1 14 B 15 B Y B B A B KL W–L KUL 15 R 5 B B B B G CPUB 12 ID2 10 W–L R 6 BB1 W–L G R G 2 BB1 1 IF1 W G–Y L–B L–Y 7 IG1 5 IC1 1 BA1 D10 DOOR LOCK CONTROL SW FRONT RH 3 W–B 1 BB1 3 UNLOCK D11 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR LH 5 LOCK 2 R–B 6 W–B D12 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR RH 6 IN1 G–B 4 M 2 IQ1 W–B A B W–B W–B L–Y W–L M 1 W–B W–B B W–B 2 1 IN1 7 BA1 R 1 J18 A , J19 B A 6 BA1 G 3 W–B D14 DOOR LOCK MOTOR, DOOR KEY LOCK AND UNLOCK SW AND DOOR UNLOCK DETECTION SW FRONT RH 4 2 BA1 W–L 5 7 BB1 R G 6 M 7 IQ1 A B R 3 6 IQ1 G 4 5 IQ1 W 2 W–B D13 DOOR LOCK MOTOR, DOOR KEY LOCK AND UNLOCK SW AND DOOR UNLOCK DETECTION SW FRONT LH 1 LOCK M 2 IN1 G 2 UNLOCK 2 IG1 1 12 IN1 L–B W–B 3 4 11 IN1 G R LOCK UNLOCK See Power Window System<18–2> 5 B A LSWD 6 6 R–B A B B A J22 A , J23 B JUNCTION CONNECTOR JUNCTION CONNECTOR B A W–L DCTY G–B J14 A , J15 B C A MPX1 16 W–L 9 2L W G L–B G R Y 2001 PRIUS (EWD414U) 18 P9 POWER WINDOW MASTER SW R C A G G 5 IG1 8 2L JUNCTION CONNECTOR A A A W–B W–B A IG J17 JUNCTION CONNECTOR Cowl side panel RH BI Left side of rear pillar M 17 PRIUS W W–G W 2001 PRIUS (EWD414U) 100A DC/DC FUSIBLE LINK BLOCK NO. 1 F11 B , F13 D 12 A BODY ECU PCTY T1 THEFT DETERRENT HORN 1 2K 3 DCTY 5 A LUG SH 20 A 17 A LSWP 9 13 A HCTY ACT+ 1 B–G Cowl side panel LH W–B W–B 120A MAIN W–B W–B IE A A A 2 1 10 IE1 9 IE1 J1 JUNCTION CONNECTOR J7 JUNCTION CONNECTOR 7 B 8 C 4 6 A A Left kick panel R3 B , R4 C BR W–B IF J27 JUNCTION CONNECTOR 9 2L IND 13 B ACT– 16 1 2J RADIO AND PLAYER Cowl side panel LH 7. 5A ECU–B A A 7 B L2 B8 A , B9 B 16 B UL2 E2 ENGINE HOOD COURTESY SW JUNCTION CONNECTOR 3 2K 10 B ACTD 8 2L BR ID R–G J24 A , J25 B 6 2L 6 RCTY 6 A RX U1 UNLOCK WARNING SW J11 JUNCTION CONNECTOR W–B W–B A B 1 2 B B 9 2C 12 KSW 15 B UL1 L–B A W–B 1 B E 14 B L1 J27 JUNCTION CONNECTOR R–G F F 9 B B 18 A LSR 4 2I C7 CENTER CLUSTER SW BATTERY F18 FUSIBLE LINK BLOCK NO. 2 5 2C 30A DOOR 8 2D 15 10 A HR See Door Lock Control System <15–4><15–5><15–6><15–7><15–8> 4 LG–B 1 5A AM1 IG1 RELAY 8 IG 4 ID2 L–B 3 5 9 2D B J26 JUNCTION CONNECTOR 3 T heft D eterrent S y stem B–W 8 2K W–G B–W R–W 2 1 W 1 2H W–L 3 2B W–L R–W 1 D 6 2D W–L 11 A BDR D D From HORN Relay<12–1> B–R LG–B 1 B ST1 IG1 4 B–Y ACC 2 B–R I15 IGNITION SW 2 AM1 1 P ow er S ource M OVERALL ELECTRICAL WIRING DIAGRAM See Interior Light System <10–2><10–3> W–B J27 JUNCTION CONNECTOR R–G 10A GAUGE 7. 5A OBDII 18 PRIUS P ow er S ource P ow er W indow 1 3 2 4 B8 A , B9 B BODY ECU ACC W–G 2 AM1 E 1 B IG1 4 IG B 9 B 15 ST1 10 10 2J 5 5K 2 2L 1 2L RLD G–R L–O B–W W L–W W W–B L–W L–O G–R 5 BB1 3 BB1 4 BB1 5 BA1 3 BA1 4 BA1 G–B L–Y W–B C R–W 11 2J 7 IB1 L–W 7 2K L–W A A L–W 3 2I L–W Y R–L W–R B–L 3 IQ1 16 9 1 IG Cowl side panel RH 1 SU SD D 2 2 1 M P13 POWER WINDOW MOTOR REAR RH E 3 U 5 1 BA1 D 2 1 2 M P12 POWER WINDOW MOTOR REAR LH W–B A J17 JUNCTION CONNECTOR A W–B 1 BB1 W–B A W–B W–B P10 POWER WINDOW MOTOR FRONT LH To Diode (Door Courtesy) <10–2> W–B M U 5 6 PCT Y 2 2 1 M P11 POWER WINDOW MOTOR FRONT RH E 3 Y 5 Y R–Y Y G O P–L 4 1 IQ1 D 2 4 W–B 8 20 U 5 SD W–B 11 3 W–B DCTY W–B 13 DU 1 SU P7 POWER WINDOW CONTROL SW REAR LH G G–R E SGND DON 6 PCT L–O MPX1 4 L–W IG P8 POWER WINDOW CONTROL SW REAR RH G B–W LMT GR 120A MAIN 12 3 Cowl side panel LH SD 18 1 IC1 J11 JUNCTION CONNECTOR 1 SU E PLS F18 FUSIBLE LINK BLOCK NO. 2 A 6 PCT W B 4 L–W WLSW 4 P6 POWER WINDOW CONTROL SW FRONT RH G G–B CPUB 1 Y 2 5 IG1 R–L W–R B–L B–G P9 POWER WINDOW MASTER SW 5 8 IC1 5 IN1 R–W 3 IC1 7 IN1 L–W 2 IC1 L–Y ID 5 J14 A , J15 B A A 1 IG1 1 BATTERY C B 3 J20 JUNCTION CONNECTOR 8 2K C B JUNCTION CONNECTOR 2 10 2K C C B RLU 1 L–W L–W 3 5 R–L 2 1 20A PWR1 IG1 RELAY B A RRU See Interior Light System <10–2> 7. 5A ECU–B 30A POWER J24 A , J25 B 1 D F11 B , F12 C , F13 D 100A DC/DC FUSIBLE LINK BLOCK NO. 1 1 C 5 POWER RELAY L–Y JUNCTION CONNECTOR B 1 B 10A GAUGE 2 1 RRD 14 5 2C 4 2D 2 1B W 2001 PRIUS (EWD414U) 15A DOME 1 2K FLD 2 A G–B 1 2H 8 2D 5A AM1 2 2G FLU 3 A 3 R–W R–G 1 7 1J DCTY W–B W W–G B–Y 6 2D 3 2B L–Y RX 6 A Y R–G I15 IGNITION SW J27 JUNCTION CONNECTOR F F BI Left side of rear pillar M 19 PRIUS W W 2001 PRIUS (EWD414U) 30A ABS NO. 2 W–B W–B B–G 120A MAIN ID A 3 1 3 6 4 3 3 14 IA2 B–W IH 6 2B Right kick panel B–L R BR Cowl side panel LH J11 JUNCTION CONNECTOR 2 3 1 Y–B BATTERY F18 FUSIBLE LINK BLOCK NO. 2 3 2 4 2 2 3 Y–G 1 B G 2 HYDRO MTR NO. 1 RELAY LG–R FUSIBLE LINK BLOCK NO. 1 2 4 1 2 HYDRO MTR NO. 2 RELAY W–B 1 D 15A AM2 F10 A , F11 B , F12 C , F13 D 2 3 2 ABS SOL RELAY 100A DC/DC 20A ABS NO. 3 8 2K 5A AM1 1 C W–R 3 1 W–L 2 IG1 RELAY 2 B W–R W–G Y–B Y–B 3 W–R 2 L–O 2 40A ABS NO. 1 1 2G 2 2I Y–B 1 B 9 1J 5 5 2A 2 10A ABS NO. 4 2 1B B–Y 1 W–G 2 2C 1 2H W 3 2B L 6 2D B–Y ST2 IG2 6 1 3 7 2A L 14 A 9 A 1 IP1 2 IP1 COMBINATION METER C10 A , C11 B 22 A 10 A L I15 IGNITION SW 7 AM2 ST1 IG1 4 ACC 3 4 L ABS 1 A B L 1 W–L 2 2 AM1 3 W 6 1K 2 ABS L 4 1K 1 P ow er S ource 3 B 2 B W–B G–W G Y–G L–O LG–R Y–B B–L GR GR–B R V–R B–W L B–W B–Y P O N M L K J I H G F E D C B A (Cont. next page) M OVERALL ELECTRICAL WIRING DIAGRAM BRAKE L G–W 5A ECU–IG 10A GAUGE 19 PRIUS (Cont’ d) (Cont. next page) ABS A B C D E 7 6 8 B–Y A L B–W 1 B V–R 9 C 5 C 10 C 2 B 12 C 3 B 4 C 11 C 3 C 6 C 2 C 8 C 1 C 7 C B1 A , B2 B , B3 C BRAKE ACTUATOR R F 5 B–Y B–W R B–W B8 A V 3 A SMC2 P 4 A SMC1 LG 9 A SRRR L G–B 8 A SRRH B–O G–W 7 A SFLR G–O R–L 21 A SFLH 6 D AST 1 D SLA+ 8 D SLA– 16 D SLR+ 7 D SLR– 2 2K GR B–W SR 19 A R1+ 7 B MR1 29 A R2+ 3 D MR2 2 D GND1 GND2 31 A MTT 6 A MT+ 27 A MT– 28 A 18 A 5 A SS PH 11 A PL 9 D LBL R–Y 6 A 1 A R–Y 3 A 5 B Y–G 2 A 1 B W–B IE Cowl side panel LH W–B A A J7 JUNCTION CONNECTOR A W–B J11 JUNCTION CONNECTOR A A W–B A W–B J1 JUNCTION CONNECTOR W–B W–B 4 B W–B W–B 4 A 1 W–B G–W 5 A W–B G–W 2 B W–B G W–B G E A E B E B J12 A , J13 B 1 E A JUNCTION CONNECTOR LG–R L–O W–B P HYDRAULIC BOOSTER W–B O H5 A , H6 B Y–B W–B N B–L R–Y From Multi Display<14–7> From Daytime R–Y Running Light Relay P2 <4–4> PARKING BRAKE SW L M 18 IA2 R–Y K PKB 13 C W–B 3 B B4 BRAKE FLUID LEVEL WARNING SW I GND4 17 B W–B LG–R 4 2 J GND3 8 B 7 C Y–R GR Y Y–G W–L W–B W–B Y–G L–O LG–R Y–B MP2+ MPX+ 11 1 C IG2 GR–B A7 A/C AMPLIFIER 22 D +BS B10 A , B11 B , B12 C , B13 D B–L 4 18 B WA L MPD1 2 B SP1 BRAKE ECU G1 GATEWAY ECU MPD2 5 B BRL B–W GR–L 11 V–R 14 R–Y MPX1 E10 ENGINE CONTROL MODULE 2001 PRIUS (EWD414U) 2 A SFRR 12 2G MPX2 GR 1 A SFRH 4 GR–B 13 H R–Y 16 A R–G 15 A G Y–B MPX– R–W MPX+ R–B 5 2B BODY ECU A A ID W–B B Cowl side panel LH M A R W B HVO– 22 B FL+ 16 A 1 FSS 24 A FR+ 14 A 1 20 D ERR (Shielded) J10 JUNCTION CONNECTOR 2001 PRIUS (EWD414U) 5 IB1 19 B RL+ (Shielded) V (Shielded) 20 B RL– 2 P P R A23 ABS SPEED SENSOR REAR LH 21 B RSS 10 B D/G 3 B TC 2 IB1 P L 1 IB1 1 19 D SG4 L A5 ABS SPEED SENSOR FRONT RH 2 FR– 13 A 13 D PRR 4 B TS RR+ 11 B 1 1 B STP RR– 2 12 B A24 ABS SPEED SENSOR REAR RH Y A4 ABS SPEED SENSOR FRONT LH 2 FL– 15 A 5 D VRR 2 A 2 E B D A 12 13 IA2 1 20 C BZ E B 23 B RRO 6 B IG1 B W–B (Shielded) W–B B A R HVO+ (Shielded) 14 B B W–B HVI– R BRAKE ECU (Shielded) 18 C SG3 B 27 C EFR W P–B 16 B 28 C PFR 6 A (Shielded) W–L HVI+ W 9 C VFR 10 A R 15 C SG2 3 A (Shielded) 24 C EREG 7 A GR–G 24 B 25 C PREG 11 A To Data Link Connector 3 <2–5><2–6> G–W B10 A , B11 B , B12 C , B13 D W 16 C VREG 4 A From Stop Light SW <3–4> G 12 A SG1 8 A B–Y G 23 A E2 12 A 11 B14 BRAKE WARNING BUZZER A 1 A B1 A , B2 B , B3 C BRAKE ACTUATOR 10 BUZZER 22 A PMC 5 A 9 B–Y 10 A VCM 9 A B–Y ABS B–Y B A 19 PRIUS (Cont’ d) J14 A , J15 B 15 B RLO JUNCTION CONNECTOR M OVERALL ELECTRICAL WIRING DIAGRAM W To EMPS ECU <20–4> (Shielded) BR BR–B (Shielded) L BR G (Shielded) (Shielded) R G To Hybrid Vehicle Control ECU <1–19><1–20> LG W–B 20 PRIUS P ow er S ource EM PS 1 2 3 W 4 3 ACC 1 IG1 4 L W–G 2 AM1 50A EMPS ST1 R–G L B–Y 22 2 3 3 2B 1 2H 2 2I 5 2A 6 2G B–R To Data Link Connector 3 <2–5><2–6> GR–G P–B W–L Y 7 D 1 C RLY B–Y 3 IP1 B W–B 2 D 7 2A Y 1 IM1 GR 8 2K 1 B B–Y 7 IA2 L W 1 A B GR 3 M 2 L L 2 E B 3 1 D1 DC MOTOR 11 5 3 IG1 RELAY W 2001 PRIUS (EWD414U) 5 D A J14 A , J15 B 14 EMPS RELAY 2 1 3 3 JUNCTION CONNECTOR 7. 5A ECU–B 10A GAUGE 5A ECU–IG 5A AM1 3 1 B–Y C10 COMBINATION METER 6 2D W W–G B–Y I15 IGNITION SW PIG 5 D WL 1 B IG 2 B M1 1 D M2 SIL 3 D 9 D TC TS F10 A , F11 B , F13 D EMPS ECU W–B 1 4 VT2 GND A B A B Right kick panel WRL 10 D From Brake ECU <19–12> IH W–B W–B Cowl side panel LH A W–B J18 A , J19 B 3 VT1 A A J11 JUNCTION CONNECTOR ID 1 S1 STEERING SHAFT TORQUE SENSOR A BATTERY 2 VCC W–B JUNCTION CONNECTOR BR 120A MAIN F18 FUSIBLE LINK BLOCK NO. 2 5 IO1 WRR 4 D (Shielded) TRQG 3 A W TRQ2 2 A (Shielded) TRQ1 4 A W W–B B–G (Shielded) 1 D TRQV 1 A B PGND 2 C G 6 2B R FUSIBLE LINK BLOCK NO. 1 B 100A DC/DC E3 A , E4 B , E5 C , E6 D J17 JUNCTION CONNECTOR A IG Cowl side panel RH M B–W B W 2001 PRIUS (EWD414U) Y–B 100A DC/DC Y–G Y–R Y–B W–B B–G 120A MAIN A20 AIRBAG SQUIB (Front Passenger Airbag Assembly) S6 SIDE AIRBAG SQUIB LH 2 1 S7 SIDE AIRBAG SQUIB RH 2 Y–R (*1) 1 SFL– 5 A Y–G (*1) SSR– SSR+ 2 F2 FRONT AIRBAG SENSOR RH 1 2 F1 FRONT AIRBAG SENSOR LH 1 2 IL1 1 IL1 4 IL1 3 IL1 Right kick panel 7 C 9 C –SL 26 B VUPR 12 C +SL 15 B ESL 9 A –SR 20 B SSL– 12 A +SR 9 B SSL+ 10 A B–W Y A21 AIRBAG SQUIB (Steering Wheel Pad) 2 SFR+ 1 C SFR– 2 C Y–G (*1) SFL+ 6 A AIRBAG SENSOR ASSEMBLY Y–R (*1) BR–W P15 PRETENSIONER RH 1 P– 11 B VUPR 7 A A17 A , A18 B , A19 C LA 3 B B–W SPIRAL CABLE 2 P+ 10 B TC SIL BR–W W–R P14 PRETENSIONER LH 1 Y 2 Y–B 1 Y 2 1 D– 13 B 19 B 12 B W–R BR W–B ID A W–B E1 27 B ESR 10 C W–B IH W–B Cowl side panel LH J11 JUNCTION CONNECTOR GR GSW2 6 2B 7 2A L BATTERY 10A SRS ACC F18 FUSIBLE LINK BLOCK NO. 2 10A ACC D+ 14 B B–O PR– 6 C G–O PR+ 5 C To Buckle SW LH <9–3> PL– 1 A G–O PL+ 2 A From Buckle SW RH <9–3> BR 1 F11 B , F12 C , F13 D L FUSIBLE LINK BLOCK NO. 1 To Hybrid Vehicle Control ECU<1–20> 23 B W RBE+ W 8 C P–B LBE+ B–Y 11 A 4 3 2 1 4 3 2 S5 SIDE AIRBAG SENSOR RH 1 S4 SIDE AIRBAG SENSOR LH P–L (*1) IG2 1 2E 9 2A C10 A , C11 B SRS WARNING LIGHT [COMB. METER] L L–W (*1) 5 B 4 2B 16 A 14 A LG–B (*1) ACC P–B 6 B 5 B To Data Link Connector 3 <2–5><2–6> GR–R GR–L (*1) E2 2 2E B J26 JUNCTION CONNECTOR B P (*1) 28 B 4 2E JUNCTION CONNECTOR GR–R 4 * 1 : w/ Side Airbags L–Y (*1) 1 D W–R 5 2B B–W LG (*1) 1 C 5A AM1 3 2E 3 2 2 2D C B J27 A , J28 B C A 3 B–Y GR (*1) 1 B 8 2K 5 1 8 2C 2 SRS L 2 1B 15A AM2 1 2H ACC RELAY 9 1J 3 2B W–G 1 2G P–L W ST2 IG2 6 ST1 IG1 ACC 3 P–L I15 IGNITION SW W–R 7 AM2 W–G 2 AM1 1 P ow er S ource GR–R 2 2C 21 PRIUS M OVERALL ELECTRICAL WIRING DIAGRAM BR 22 PRIUS P ow er S ource R ear W indow D efogge r 1 R ad iator F an and C ondens er Fan 2 3 W 4 B–Y 4 1J 3 1B W–G ACC 2 AM1 GR–R IG1 4 1 1 2H 4 2M 30A RDI 7 2G 13 2 5 3 2 1 40A DEF 5A AM1 DEF RELAY 1 5 4 3 5 3 FAN NO. 1 RELAY 1 30A CDS FAN 3 2B B–Y 6 2D B8 A DFG BODY ECU 15 A MPX+ B W W–G I15 IGNITION SW B–Y ST1 2 1 FAN NO. 2 RELAY 5 FAN NO. 3 RELAY 2 3 2 1 2 5 7 1K 7 IE1 To A/C Amplifier <24–6> V–Y M 2 V–Y V–Y J27 A , J28 B JUNCTION CONNECTOR E A E A A B V–Y 11 A MPX+ N4 NOISE FILTER (Rear Window Defogger) SW RDEF A 11 IE1 V–Y PSG J7 JUNCTION CONNECTOR A W–B ID 1 A W–B W–B Cowl side panel LH 3 3 A7 A/C AMPLIFIER J11 JUNCTION CONNECTOR MPX– To A/C Amplifier <24–7> C11 COMBINATION METER REAR WINDOW DEFOGGER SW A W–B BATTERY MPX+ 12 1J 2 W–B 120A MAIN F18 FUSIBLE LINK BLOCK NO. 2 2 GR REAR WINDOW DEFOGGER 1 W–B 5 1K G–W B–G 1 6 IE1 W–G B 1 D A3 A/C SINGLE PRESSURE SW GR–R W–B 100A DC/DC F11 B , F13 D FUSIBLE LINK BLOCK NO. 1 2 1K A1 A/C CONDENSER FAN MOTOR 1 B 10 1J R–W 8 2K L–W 1 5 1J To Engine Control Module<2–13> M R1 RADIATOR FAN MOTOR 2 11 1A LG W–B L–W 5A ECU–IG 10A GAUGE 3 3 1K R–W IG1 RELAY 2 W W 2001 PRIUS (EWD414U) 1 2 A J1 JUNCTION CONNECTOR Cowl side panel LH W4 WATER TEMP. SW IE 1 W–B M 23 PRIUS L W–G W L–Y B 100A DC/DC 15A DOME 2001 PRIUS (EWD414U) 1 B–G W–B 120A MAIN 6 2B TC 1 1 A 7 B 6 B 9 A 1 B See Back–Up Light System<6–3> BR W–B IH L H8 ODO/TRIP SW [HAZARD WARNING SW] Right kick panel 5 ODO 3 L E 3 A See ABS System <19–4> Cowl side panel LH J11 JUNCTION CONNECTOR L 7 2A 2 A L ID A 14 A From Navigation ECU<14–5> BATTERY F18 FUSIBLE LINK BLOCK NO. 2 5A AM1 1 D L F11 B , F12 C , F13 D L FUSIBLE LINK BLOCK NO. 1 L 8 2K L 11 A 13 A 22 A 21 A 20 A 12 A L 1 B 5 IP1 5 6 BUZZER FUEL SENDER 1 COMBINATION METER C10 A , C11 B SENSOR L–R 3 4 IP1 L–Y IG1 RELAY 6 2A MPX+ 15 A FU– 19 6 2J 8 2J 9 2J Y 1 C B–Y Y–B 2 1B W–G VFD V–W 5 W JUNCTION CONNECTOR 8 FU+ 11 16 A MPX– BR–R BR–R 2 B F16 FUEL SENDER 2 1 R–G 5 2A J27 JUNCTION CONNECTOR 5 2C L 1 2H 4 L–W BODY ECU 3 2B V–W 7 2B L–Y Y 6 2D G A 20 FUA 9 B B Y–B I15 IGNITION SW G B V–W G A J27 A , J28 B G B V–W From Multi Display <14–7> R–G GR–B 7 1J IG1 4 From Hybrid Vehicle Control ECU<1–19> From Engine Control Module<2–13> G V–W A 3 B8 A , B9 B ST1 2 4 MPD2 MPX1 3 B GR 11 MPX+ MPX– 4 4 MPD1 11 14 MPX2 GR–L 13 E10 ENGINE CONTROL MODULE GR GR–B 2 2G 2 AM1 ACC F F R–G C ombination M eter G1 GATEWAY ECU 4 2A 1 P ow er S ource (Cont. next page) M OVERALL ELECTRICAL WIRING DIAGRAM A7 A/C AMPLIFIER HEAD DOOR See EMPS System <20–4> See Illumination System<8–4> 10A GAUGE 7. 5A ECU–B 23 PRIUS (Cont’ d) C ombination M eter 17 A 18 A 19 A 5 B See Headlight System <3–3><4–4> See Turn Signal Light System<5–4> See SRS System <21–3> HIGH BEAM TURN R TURN L SRS ABS MALFUNCTION INDICATOR LAMP SEAT BELT (Front Passenger’ s Seat) WATER TEMP. (High) WATER TEMP. (Low) CRUISE OUTPUT CONTROL CHARGE OIL SEAT BELT (Driver’ s Seat) BRAKE 2001 PRIUS (EWD414U) 16 A 10 A 4 B C10 A , C11 B 8 7 6 5 COMBINATION METER See SRS System <21–3> See ABS System <19–4> See Engine Control System<2–4> M 50A HTR3 30A HTR2 B 30A HTR1 W 2001 PRIUS (EWD414U) J6 JUNCTION CONNECTOR 100A DC/DC B–G W–B 120A MAIN A J7 JUNCTION CONNECTOR A W–B Cowl side panel LH W–B A W–B L–R 1 W–B W–B IE A A/C W/P RELAY L M 1 W–B ID A Cowl side panel LH J11 JUNCTION CONNECTOR 13 IE1 R A 3 R J6 JUNCTION CONNECTOR J1 JUNCTION CONNECTOR 3 B B R 4 2 R GND 5 2 B R B7 BLOWER MOTOR LINEAR CONTROLLER V SI W–B A B C A JUNCTION CONNECTOR J22 A , J23 B C A R 8 2D V LG–R MGC 10 B 8 IE1 BLW 3 A 21 IE1 PSW 11 B IG 1 A WP 3 B 20 IE1 15 IE1 GND A A A B 7 A B–L J24 A , J25 B BATTERY F18 FUSIBLE LINK BLOCK NO. 2 B–W +B B–R VM 3 1 LG–R 3 4 L–Y 3 2D R 2 3 R 8 2K +B A7 A , A8 B , A9 C A/C AMPLIFIER L–Y 1 B–L 3 R 3 1K 8 A F J27 JUNCTION CONNECTOR L–O R–L G G–W B–R F E D C B A (Cont. next page) JUNCTION CONNECTOR W–B W–B 1 B–R A A V 4 1F 10A HTR F LG–R B6 M BLOWER MOTOR 2 A B J2 A , J3 B 3 1F 3 2 IG1 RELAY 5 2C 4 R L–R 1 D 50A HTR JUNCTION CONNECTOR 5 1A 2 8 2G V FUSIBLE LINK BLOCK NO. 1 1 A A B–R F10 A , F11 B , F13 D A A L–O L–Y 1 A W 1 13 1J 3 5 1 1 2H 7. 5A ECU–B L–R 1 B B–R 3 G–W 8 1K 3 CLR MG RELAY 5A AM1 3 1B 1 2 HTR RELAY 1 6 2D 3 2B 10A GAUGE 1 2 4 5 I15 IGNITION SW B–Y 3 R–G 1 2 G 3 5 ST1 IG1 4 ACC W–G 1 2 AM1 W 3 2 W–G 2 A ir C onditioning R–L 3 1 P ow er S ourc e R–G 2 24 PRIUS M OVERALL ELECTRICAL WIRING DIAGRAM W–B A3 A/C DUAL PRESSURE SW W2 WATER PUMP MOTOR (A/C) 24 PRIUS (Cont’ d) (Cont. next page) A ir C onditioning 5 A B C D 7 6 8 B–R B–R G–W G–W G G R–L R–L A B C D B8 A BODY ECU MPX+ 15 A MPX– 16 A 5 IA2 W–G 11 MPX+ MPX– MPD2 C11 COMBINATION METER 3 E2 22 D E 8 B , E 9 C , E10 D SGTPI 20 C S5TPI 18 C TPI 19 C AIF 22 C AIR 21 C 4 C RF TR 3 C 1 C SGTR S5TP 17 C TE SGTP 15 C TP 16 C W TS 1 B W ACT 5 C 1 W 5 B W BR–W 2 C SGTE AMC 14 C AMH 13 C W W W W W W W W W W W 6 II1 2 9 II1 10 II1 BR–R L Y–R 1 7 II1 BR–Y W–R A11 A/C SOLAR SENSOR 8 II1 BR–W 4 2 2 1 2 IK1 BR 1 1 A6 AMBIENT TEMP. SENSOR ENGINE CONTROL MODULE 18 B W From Converter <1–13> From FAN NO. 3 Relay <22–4> BR–W B–L 5 IK1 W–L F S5TS 6 C ACT 1 5 IE1 W–L 4 IK1 IDH 10 A Y 4 IE1 V–Y BR–W W–L A/C AMPLIFIER CF 2 B NE 2 23 C TAM R–W SGLOCK 18 B 4 B MP2+ 13 D MPX2 P–G LOCK 9 B LG GR–B GR 2001 PRIUS (EWD414U) 4 A MPX+ NEO 3 D 4 11 A A7 A , A8 B , A9 C G1 GATEWAY ECU MPD1 14 D MPX1 W–G A12 A/C THERMISTOR 2 L–O GR E GR–L A10 A/C ROOM TEMP. SENSOR GR–B 6 2F From FAN NO. 1 and FAN NO. 2 Relay<22–4> HRLY 18 2 3 4 5 1 2 3 4 5 2 A2 A/C MAGNETIC CLUTCH AND LOCK SENSOR M A14 AIR INLET CONTROL SERVO MOTOR M A15 AIR MIX CONTROL SERVO MOTOR M D C B A W W W 2001 PRIUS (EWD414U) 3 W 2 5 HTRO 13 B HTR2 LED LED RDEF FULL A/C 6 B LED F/R P–B P R GR–L BR–W W 3 4 B 3 B 2 B 1 B P–B ID A Cowl side panel LH A 5 IA1 1 IA1 W–B W–B Y–B Cowl side panel LH J1 JUNCTION CONNECTOR 16 IE1 5 3 1 HTR2 RELAY R–L W–B IE A 2 A 1 A 3 5 3 18 IE1 2 3 W–B M 4 A/C AMPLIFIER LED A/C HTR3 RELAY 3 3 2 L–Y 1 W 1 II1 PIG A7 A , A8 B , A9 C SW SW RDEF FULL A/C 3 P 2 II1 AOD 11 C SW F/R R–L 4 II1 AOF 10 C SW A/C 3 L–R 3 II1 TPM 8 C PSG 3 R–L 11 P–B 5 II1 9 C SGTPM MSET PIG5 1 G 7 C TSET 10 G–W W–B A16 AIR VENT MODE CONTROL SERVO MOTOR BSET 9 A ir C ondition ing J11 JUNCTION CONNECTOR PTC HEATER P3 A , P4 B G–R 5 2 3 3 3 1 3 3 B–R S5TPM R–L G G–W B–R 24 PRIUS (Cont’ d) HTR1 RELAY 12 M OVERALL ELECTRICAL WIRING DIAGRAM P–B FOREWORD To assist you in your sales and service activities, this manual explains the main characteristics of the new PRIUS, in particular providing a technical explanation of the construction and operation of new mechanisms and new technology used. Applicable models: NHW11 series This manual is divided into 4 sections. 1. Introduction – Exterior appearance and model code. 2. New Model Outline – Explanation of the product to give a general understanding of its features. 3. Technical Description – Technical explanation of the construction and operation of each new system and component. 4. Appendix – Major technical specifications of the vehicle. CAUTION, NOTICE, REFERENCE and NOTE are used in the following ways: CAUTION A potentially hazardous situation which could result in injury to people may occur if instructions on what to do or not do are ignored. NOTICE Damage to the vehicle or components may occur if instructions on what to do or not do are ignored. REFERENCE Explains the theory behind mechanisms and techniques. NOTE Notes or comments not included under the above 3 titles. For detailed service specifications and repair procedures, refer to the following Repair Manuals: Manual Name
2001 PRIUS Repair Manual
2001 PRIUS Electrical Wiring Diagram Pub. No. RM778U EWD414U All information contained herein is the most up-to-date at the time of publication. We reserve the right to make changes without prior notice.  2000 TOYOTA MOTOR CORPORATION All rights reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of Toyota Motor Corporation. First Printing: Apr. 5, 2000 01-000405-00 2 EXTERIOR APPEARANCE 182IN01 182IN02 3 MODEL CODE AND MODEL LINE-UP MODEL CODE NHW11 L – A E E E B A 1 1 2 3 2 3 BASIC MODEL CODE 4 5 NHW11: With 1NZ-FXE Engine STEERING WHEEL POSITION 6 L: Left-Hand Drive MODEL NAME 7 A: Prius 5 6 7 GEAR SHIFT TYPE E: Automatic, Column GRADE E: Standard ENGINE SPECIFICATION B: Atkinson DESTINATION 4 BODY TYPE 8 E: 4-Door Sedan A: U.S.A. K: Canada MODEL LINE-UP TRANSAXLE DESTINATION ENGINE BODY TYPE GRADE Automatic P111 U.S.A. Canada NHW11L-AEEEBA 1NZ FXE 1NZ-FXE Sedan Standard NHW11L-AEEEBK 8 4 – MEMO – 10 NEW MODEL OUTLINE INTERIOR An interior which reflects the type of comfort that will be regarded as a must in cars hereinafter. Package The Prius package gives highest priority to driver and passenger comfort.



A spacious cab that is hard to imagine in a car of this size. Spacious head clearance for a more open feel. Ideal seat height for easy access. An easy-to-use luggage compartment with ample space. Spacious head clearance for a more open feel High point of vision for easier understanding of surrounding conditions 182MO05 Ideal hip point height for easy access Easy-to-use luggage compartment with ample space Instrument Panel The instrument panel is a balanced combination of functionality and symmetry.
Human-engineered layout perfectly suited to the new age, with centrally positioned operational functions. Multi–Information Display Meter 182MO06 11 NEW MODEL OUTLINE Meter A digital-display combination meter is located in the uppermost, center position of the instrument panel. This ensures ease of visual confirmation, including that of all indicators. (For U.S.A.) 182MO07 Seat [Front Seat]
The pads fitted on the side of the seatback are of a different degrees of hardness, ensuring a superior hold.
A seatback pocket has been included on the front seat providing additional and convenient storage space. Driver’s seat Passenger’s seat Seat back pocket (Driver’s and passenger’s seat) 182MO09 182MO08 CRS anchor bracket [Rear Seat]
Three CRS anchor brackets that FMVSS225-certified have been fitted on the top section of the package tray trim to facilitate the mounting of child seats.
An FMVSS225-certified child-seat CRS lower anchorage is fitted on both outer-side seats. A A Child seat Seat Back Child seat CRS lower anchorage Seat Cushion 182MO10 A – A Cross Section 12 NEW MODEL OUTLINE MAIN MECHANISM Low-emission & high-fuel efficiency. TOYOTA hybrid system leading the way into the next generation. Tackling the challenge for high fuel efficiency and low emissions Prius - the mass-production gasoline hybrid vehicle - already meets all of the various strict emission levels being proposed throughout the world, well ahead of the competition. What’s more, through the use of the hybrid system, surpassing fuel efficiency and a massive reduction in CO2 has become a reality. The Prius can truly be acclaimed as “the clean and environmentally friendly vehicle.” Emission Reduction Features 1. Precision Emission Control Through full utilization of the two Oxygen sensors, precision emission control is made possible even when the engine is frequently stopped and re–started. Furthermore, excellent purification of exhaust gas is ensured through the catalytic converter, resulting in reduced emissions. 2. Vapor Reducing Fuel Tank System We have developed a new fuel tank system that can dramatically reduce the amount of fuel vapor generated in the tank both when the vehicle is moving as well as when it is at a standstill. This system is the first one in the world to be used. 3. TOYOTA HC Adsorber and Catalyst System A new system has been adopted which adsorbs the HC that is emmitted between the time the engine is coldstarted and the catalytic converter is still cool and not yet activated, until the time the catalytic converter becomes active. After the catalytic converter has been activated, the HC disassociates little by little and is then purified. 4. Adoption of a Thin-walled High-density Cell Catalytic Converter In order to reduce the amount of time taken until the catalytic converter is activated, we developed a catalytic chamber with a super thin ceramic wall. Also, high-density cells have been utilized as a measure to improve strength and increase contact area with exhaust gas. Through these measures we have been able to achieve a balance of reliability and purification efficiency. 13 NEW MODEL OUTLINE TOYOTA Hybrid System (THS) The TOYOTA hybrid system has two drive sources, one is the gasoline engine and the other, the AC motor. The power train system selects the best combination of the different characteristics of both depending on driving conditions. Also, through the adoption of a regenerative braking system, which recovers energy during deceleration and “idling stop” whereby the engine is stopped during idling, we have been able to provide for maximum energy conservation. This has resulted in a vastly superior fuel economy compared with that of gasoline A/T vehicles of the same displacement. Gasoline engine + AC motor = TOYOTA Hybrid System (THS) Tremendous improvement in fuel efficiency & clean achieved! Features of the System 1. Optimum distribution of drive sources The most efficient engine operating zone is automatically selected by controlling the optimum distribution of the engine and motor drive energy sources. 2. Reduced energy loss The engine is automatically stopped when starting and travelling at low load to reduce fuel consumption.*1 The kinetic energy that used to be lost through engine or foot braking is recovered by the regenerative braking system and used for recharging, thereby contributing to improved fuel efficiency. When the driver applies the brakes, the hydraulic and regenerative braking systems are coordinated. In order to recover more energy, a higher proportion of regenerative braking is used. 3. Not required for recharging from an external source The system uses MG1 (Motor Generator No.1) and MG2 (Motor Generator No.2) to maintain a constant battery charge, so unlike an electric vehicle, recharging from an external source is not required. *1 : In some cases, the engine does not stop, depending on the air conditioner and HV battery (Hybrid Vehicle Battery) status. System configuration  P111 HYBRID TRANSAXLE Fitted with built-in THS transaxle MG1 (Motor Generator No.1), MG2 (Motor Generator No.2), power spliting device and reduction gears for the hybrid system. These function to switch engine operation to MG2 assistance, HV battery charging and power generation for driving MG2.  Inverter This controls the current between MG1, MG2 and HV battery and converts DC/AC power.  HV Battery (Hybrid Vehicle Battery) This supplies power to the motor at full load or on engine stopping and stores power recovered by regenerative braking or power generation by MG1. 228 nickel-metal hydride batteries are connected in series to obtain a voltage of 273.6 V DC. 1NZ-FXE engine HV battery Inverter 182MO11 P111 Hybrid transaxle Hybrid transaxle 182MO12 14 NEW MODEL OUTLINE MAIN MECHANISM THS operation Starting and traveling at low load When the engine efficiency is low such as when starting, traveling at low load or the engine is stopped, permitting travel by MG2; (however the engine may start under SOC (State Of Charge) of the HV battery.) 182MO13 Normal traveling The engine energy is divided into two. One portion directly drives the wheels. The other portion drives MG1 to drive MG2 by generated power, which also drives the wheels. 182MO14 Full acceleration In addition to the 2-way system for normal travelling, the drive power of MG2 is further supplemented by the power stored in the HV battery, resulting in powerful and smooth acceleration. 182MO15 Deceleration or braking The wheels drive MG2 which acts as the generator for regenerative power generation. The power recovered by generation is stored in the HV battery. 182MO16 Stopped When the vehicle is stopped, the engine stops automatically. However, when it is necessary to charge the HV battery or to run the air conditioner compressor, the engine will not stop. 182MO17 15 NEW MODEL OUTLINE HV Battery Charging When high load operation is continued, the engine does not stop to charge the HV battery even if the vehicle is stopped, in order to keep the HV battery charged to a given level. (when “READY” light is ON.) ;however, the engine does not charge the HV battery when the lever is shifted into the “N” position. 182MO18 The engine speed may also be increased during normal traveling in order to charge the HV battery. 182MO19 1NZ-FXE Engine The new Prius is fitted with a 1.5
gasoline engine which has been developed for the use with the TOYOTA hybrid system. A mass of leading-edge technology has been implemented to achieve excellent fuel economy, low emissions, light weight, compactness, and low vibration and noise. Outline of the 1NZ-FXE Engine Engine performance curve 1NZ-FXE Type Bore × Stroke DOHC 4 valves (mm) Compression ratio Maximum output (52/4,500) 75.0 × 84.7 13.0 [kW (HP)/rpm] 52 (70)/4,500 Maximum torque [N·m (lb·ft)/rpm] 111 (82)/4,200 Fuel kW 60 1,497 Gasoline 50 N·m 120 110 100 90 80 40 (111/4,200) 30 20 10 1,000 2,000 3,000 4,000 5,000 Engine Speed (rpm) 182EG03 Output (m
) Torque Displacement 16 NEW MODEL OUTLINE MAIN MECHANISM 4 Features of the 1NZ-FXE engine 1. Highly efficient and high expansion ratio gasoline engine Adoption of a super fuel-efficient engine developed for use with THS. Its high expansion ratio cycle is achieved by applying the Atkinson cycle*1 which obtains high thermal efficiency. 2. Reduction in frictional loss The maximum engine speed is set at 4,500 rpm to reduce frictional resistance, thereby producing a highly efficient low-speed engine.
An offset crankshaft with 12 mm deviation from the center axis of the cylinder bore is utilized to reduce frictional resistance of the piston.
Frictional resistance is reduced through the use of low tension valve springs and piston rings.
Lightweight design has been adopted for reciprocating engine parts. The above measures for reducing frictional loss contribute to improved fuel economy. 3. VVT-i (Variable Valve Timing -intelligent) The timing of the opening and closing of the intake valves is controlled by the computer according to driving conditions, such as engine speed and level of acceleration. Thus, smooth intake and exhaust are achieved to greatly improve torque in the low and medium speed zones. This also contributes to better fuel economy and purification of exhaust gas. Then the VVT-i function is used to reduce vibration when the engine starts. 4. Compact, lightweight, and low emission Adoption of an aluminum cylinder block and compact design of parts. And, by positioning the catalytic converter near the engine for a backwards exhaust layout, we have been able to reduce emissions when the engine is cold started. *1 : Atkinson Cycle: Proposed by an English engineer named James Atkinson, this thermal cycle enables the compression stroke and the expansion stroke of the mechanism to be set independently of each other. Suspension MacPherson strut type suspension with L-shape lower arms has been adopted in the front and torsion beam with toe control link suspension in the rear. Also, each component part is optimally located and tuned for both excellent controllability and enhanced riding comfort. 182CH29 EMPS (Electric Motor-assisted Power Steering) System Vehicle speed sensing type electric motor-assisted power steering is fitted as standard. Unlike conventional hydraulic power steering, EMPS does not depend on an engine for its power source, providing a steering feel in no way inferior to conventional steering when the engine has stopped. Thus it is suitable for the HV system. Other merits include improved fuel economy through energy conservation, lighter weight, and no need to fill the power steering fluid. 17 NEW MODEL OUTLINE MAIN EQUIPMENT A range of features for comfort - the more you use them, the better they get. Multi-Information Display
The 5.8” wide touch panel type multi-information color LCD is standard.
Energy monitor, fuel consumption and other vehicle information screens, audio operation status and audio operation screen can be indicated on the multi-information display. The outside temperature are also indicated on the screen. [Audio system]
An AM/FM cassette and 4-speaker system compatible with the multi-information display has been adopted.
As the touch panel type display is used to operate the audio system, the multi-information display simultaneously indicates the operating status of the audio system.
The antenna provided is a collapsible style pole antenna positioned at the center of the roof. [GPS Voice Navigation]
A GPS (Global Positioning System) voice navigation system is optional.
The multi-information display can show the map on favorite type among turn list, arrow display and enlarged intersection.
Using DVD (Digital Versatile Disk) as a memory source for map data, a large quantity of information can be processed. 182MO20 [Information Screen] This screen indicates the direction of energy transmission. It is also possible to check the current drive method (engine, motor or both) and status of power generation by the engine and that of charging regenerative energy.  Main Function of the Multi-information Display Screen Function Enlargement / reduction, rotation and movement of map Map screen display dis lay ((option)) Indication of current position and direction of travel Correction of current position Setting, change and indication of route Voice guidance Indication of enlarged intersections Memory and indication of map position Audio screen Information screen Status of audio equipment and audio operation screen indication Energy monitor screen indication 182BE36 This screen indicates the average fuel consumption, amount of recovered energy and fuel consumption for that moment. Average fuel consumption is displayed at 5-minutes intervals. The recovered energy display indicates the amount of energy recovered over the past 5 minutes, with each mark representing 50Wh. Fuel consumption screen indication Sound quality adjustment screen indication Adjustment Adj t t screen Image quality adjustment screen indication No indication On screen On-screen indication Interrupt screen Diagnosis screen display Audio status indication Warning indication Warning indication Displays system diagnosis Displays various types of coefficient settings 182BE37 18 NEW MODEL OUTLINE MAIN EQUIPMENT Air Conditioning An automatic air conditioning has been adopted in consideration to ease of use.
A clean air filter which removes pollen and dust is included as a standard fitting for purifying the air inside the cab.
Two air conditioning modes, A/C for economical air conditioning and MAX for especially strong air conditioning, are provided. (For U.S.A.) 182MO23 Wireless Door Lock Remote Control System With the wireless door lock remote control system, all the doors can be locked and unlocked by signals emitted by the transmitter. Power Window System A power window system which enables all windows to be raised or lowered with switches has been adopted. An auto up/down function and jam protection function have been added to the driver’s power window. HV Immobiliser System HV immobiliser system will not allow the HV system to be started by duplicate key is used. This system will permit the HV system to be started only when the ID code of the transponder chip impregnated in the key matches the ID code registered beforehand in the transponder key amplifier. Theft Deterrent System When an attempt is made to forcibly enter the vehicle or open the hood or trunk lid without a key, or when the battery terminals are removed and reconnected, this system sounds the horn and flashes the headlights, taillights and emergency flashers for about 1 minute to alert the owner. At the same time, it locks all the doors. Storage Space Ample storage space with an emphasis on practicality provided throughout the Prius. Instrument panel (passenger seat) Seat back pocket Multi-box Accesory box Glove box 182MO24 Seat back pocket (Driver’s and passenger seat) Front door pocket 182MO09 Center console box Front door pocket 182MO25 Luggage space 182MO28 Small storage box 182MO27 182MO26 Cup holder (for two caps use) 11.839ft3 (by SAE suitcase method) luggage space is secured. 19 NEW MODEL OUTLINE SAFETY Prius – one step ahead of the rest even in the area of safety. Drive with the utmost peace of mind. Passive Safety Body The impact absorbing body adopted for the new Prius effectively absorbs and distributes the impact from front and side collisions to ease the effects of the impact on the driver and passengers, and the high-strength body structure minimizes deformation of the cabin itself. [Frontal collision] The front section of the body frame and under body absorb and distribute the load generated by a frontal collision, while the strong cabin frame eases the effect of the impact on the driver and passengers and minimizes deformation of the cabin, thus realizing an ideal body structure. The front side member is of a straight design to be deformed effectively from the front end. Also, in the event of a front collision, the force of the impact is effectively distributed to each of the braces and members through the sections where they join the cabin. 182MO29 182MO30 [Side collision] Along with the ideal body structure which effectively absorbs and distributes the load on the frame in side collisions, we have maintained the strength of each pillar, rocker panel and door to minimize deformation of the cabin. Side Impact Energy 182MO31 20 NEW MODEL OUTLINE SAFETY Head Impact Protection Structure The construction of the pillar trims and roof side adopted gives full consideration to protecting the heads of the driver and passengers from injury in the event of a collision. In addition, impact absorbing material has been built into the interior of each pillar trim and roof side which are most likely to be the cause of head injuries in a collision. EA rib (side rail front specer) Aluminum EA Material EA : Energy Absorbing EA rib (side rail rear specer) EA rib (center pillar garnish pad) 182MO32 SRS Airbag SRS airbags are standard for the driver and front passenger seats on all models. In the event of a frontal collision, the airbags function to support the seatbelts in reducing the impact to the driver and front passenger. Also, SRS side airbags are available as a option. The SRS side airbags have been designed to help reducing the impact energy that is transmitted to the driver and front passenger in the event of a side collision. Seatbelt with Pre-tensioner and Force-limiting Mechanism Three-point type seatbelts with pre-tensioner and force limiter are standard on the front seats of all models. An ELR-equipped seatbelt is provided on the driver’s side and an ALR/ELR selectable one on the passenger side. Three sets of 3-point type ALR/ELR selectable seatbelts are fitted on the rear seats. 6 NEW MODEL OUTLINE CONCEPT Introducing the Prius – the car that is friendly to both the earth and to people! ... and announcing of a new feel of future worth. When we consider the future of the earth, this car was deemed to become a necessary part of it. A car that is unbelievably friendly and comfortable while still maintaining a high degree of practicality... The answer to this is the car we would like to present to you here – the Prius. A streamlined and artistic exterior design combined with a safety features that would make anyone feel at ease. What’s more, through selecting the TOYOTA hybrid system which effectively utilizes 2 power sources – electricity and gasoline – we have been able to achieve world top-class level fuel economy and low emissions. TOYOTA is proud to present the “Hybrid Car Prius” as a car that is ideal for now and well into the future as well. The Prius leads the way in the showing direction that cars must go in the 21st century. 182IN01 NEW MODEL OUTLINE Prius – a 4-door compact sedan 5 Features to lead the way into the next generation POINT1 Exterior Futuristic image and symmetry are reflected in the artistic design of the new Prius. POINT2 Interior An interior which reflects the type of comfort that will be regarded as a must in cars hereinafter. POINT3 Main Mechanism Low-emission & high-fuel efficiency. TOYOTA hybrid system leading the way into the next generation. POINT4 Main Equipment A range of features for comfort - the more you use them, the better it gets. POINT5 Safety Prius - one step ahead of the rest even in the area of safety. Drive with the utmost peace of mind. 7 8 NEW MODEL OUTLINE EXTERIOR Futuristic image and symmetry are reflected in the artistic design of the new Prius. Front Design A short slanted hood highlights the singular front design.
The defined character lines from the front fender curving around to the rear give off a fresh appeal.
Crystal-look front combination lamps and compact grille finish off the masked look. 182IN01 1,465 (57.6) mm (in.) 1,695 (66.7) 182MO01 Rear Design The simple rear design gives out an impression of stability.
Three-dimensional panel make-up produces a perfect balance in its feeling of presence and stability for the rear view.
The rear combination lamps extend around to the sides, giving emphasis to the wide image. 182IN02 9 NEW MODEL OUTLINE Side Design A mono-form silhouette is the basis of the ultra modern side view.
The short overhang adopted reflects the consideration given to minimize the turning radius. And the long wheelbase brings better riding comfort and spacious cabin. Short front overhang Short rear overhang Long wheelbase mm (in.) 2,550 (100.4) 4,305 (169.6) 182MO02 Aerodynamics The upper body profile provides smooth airflow through the free use of computer simulation. Furthermore, the front tire fairing, rear tire fairing, rear spoiler and flat under-body, among others achieve an excellent drag coefficient of CD = 0.29. CD = 0.29 attained! Rear spoiler Front tire fairing Rear tire fairing 182MO03 Disc Wheel Aluminum wheels are fitted standard on all models. Size Design P175/65 R14 5 1/2JJ 182MO04 43 ENGINE – INZ-FXE ENGINE ENGINE 1NZ-FXE ENGINE DESCRIPTION The Prius uses the 1NZ-FXE engine that has been newly developed for hybrid system application. Based on the 1NZ-FE engine, the high-expansion ratio Atkinson cycle has been adopted. It is an in-line 4-cylinder, 1.5-liter, 16-valve DOHC engine. This engine has adopted the VVT-i (Variable Valve Timing-intelligent) system has been developed to realize high performance, quietness, fuel economy and clean emissions. 182EG01 – REFERENCE – 182EG02 Atkinson Cycle: Proposed by an English engineer named James Atkinson, this thermal cycle enables the compression stroke and the expansion stroke of the mechanism to be set independently of each other. Later, this concept was realized by the American R. H. Miller, who developed a system called the Miller Cycle in which the opening and closing timing of the intake valves was made adjustable. Because this system does not generate high output, there is no practical application for this system unless it is combined with a supercharger; however, this system offers a high level of thermal efficiency. On Prius, this weak point can be covered by combining the Atkinson cycle engine with THS. 44 ENGINE – 1NZ-FXE ENGINE
Engine Specifications  Engine Type No. of Cyls. & Arrangement Valve Mechanism 1NZ-FXE 1NZ-FE (ECHO) 4-Cylinder, In-line
16 Valve DOHC, Chain Drive
Pentroof Type
Cross-Flow
SFI
1497 (91.3)
75.0 x 84.7 (2.95 x 3.33)
13.0 : 1 10.5 : 1 Combustion Chamber Manifolds Fuel System Displacement cm3 (cu. in.) Bore x Stroke mm (in.) Compression Ratio Max. Output [SAE-NET] 52 kW @ 4500 rpm 70 HP @ 4500 rpm 81 kW @ 6000 rpm 108 HP @ 6000 rpm Max. Torque [SAE-NET] 111 N.m @ 4200 rpm 82 lb-ft @ 4200 rpm 142 N.m @ 4200 rpm 105 lb-ft @ 4200 rpm Open 18
–25 BTDC –7
53 BTDC Close 72
115 ABDC 52
–8 ABDC Open 34 BBDC 42 BBDC Close 2 ATDC
91 or more
API SJ EC or ILSAC
Intake Valve Timing g Exhaust Fuel Octane Number RON Oil Grade Performance Curve  kW 60 50 N.m 120 110 100 90 80 40 Output Torque
30 20 10 0 1000 2000 3000 4000 5000 Engine Speed (rpm) 182EG03 45 ENGINE – 1NZ-FXE ENGINE FEATURES OF 1NZ-FXE ENGINE The 1NZ-FXE engine has been able to achieve the following performance through the adoption of the items listed below. (1) High performance and fuel economy (2) Low noise and vibration (3) Lightweight and compact design (4) Good serviceability (5) Clean emission Item (1) The VVT-i system is used.  High-expansion Atkinson cycle has been adopted.  An offset crankshaft has been adopted.  (2) (4) (5) 1NZ-FE     A cylinder block made of aluminum has been adopted. (3)      A rearward exhaust layout has been adopted to realize the early activation of the catalyst.   HC Adsorber and catalyst system has been adopted.  Fuel returnless system has been adopted.     A stainless steel exhaust manifold is used for weight reduction. 12-hole type fuel injectors have been adopted.  The DIS (Direct Ignition System) makes ignition timing adjustment unnecessary.   Quick connectors are used to connect the fuel hose with the fuel pipes.   The oil filter is installed diagonally downward.   A timing chain has been adopted.   A vacuum system that detects leaks in the evaporative emission control system has been adopted.  The vapor reducing fuel tank system has been adopted. This system reduces the amount of fuel vapor that is generated.    46 ENGINE – 1NZ-FXE ENGINE ENGINE PROPER 1. Cylinder Head
The angle of the intake and exhaust valves is narrowed and set at 33.5 to permit a compact cylinder head.
As a result of installing the injector in the intake port of the cylinder head, the contact of the fuel against the intake port wall has been minimized and fuel economy has been improved.
A water jacket has been provided between the exhaust port and the spark plug boss in order to maintain the combustion chamber wall temperature uniform, thus improving the cooling performance of the combustion chamber and the area around the spark plug. Valve Angle 33.5 Water Jacket 182EG04 47 ENGINE – 1NZ-FXE ENGINE 2. Cylinder Block
A cylinder block made of aluminum alloy has been adopted to realize a significant amount of weight reduction.
A water pump swirl chamber and an inlet passage to the pump are provided in the cylinder block.
The rear portion of the cylinder block has been shaped conically to improve the coupling rigidity with the transaxle.
Through the adoption of the offset crankshaft, the bore center has been shifted 12 mm towards the intake, in relation to the crankshaft center. Thus, the side force when the maximum pressure is applied has been reduced and the heat efficiency has been improved. And as a result, fuel economy has been improved.
Through the use of a thin-walled cast iron liner in the cylinder bore, a distance of 8 mm between the bores has been realized, resulting in a compact package. This liner is thin, so that boring is not possible.
By discontinuing the use of the rear oil seal retainer and by pressing the rear oil seal into the cylinder block, a compact package has been realized. Front Exhaust Side 12 mm Crankshaft Center Bore Center 8 mm Intake Side 182EG05 3. Piston
The taper squish shaped piston has been adopted to improve combustion chamber. Taper Squish Shape
Low-tension piston rings have been adopted to reduce friction and improve fuel economy and oil consumption performance.
By increasing the mechining precision of the cylinder bore diameter, the outer diameter of the piston has been made into the one type. 182EG06 48 ENGINE – 1NZ-FXE ENGINE 4. Connecting Rod
The connecting rods are made of high-strength material for weight reduction.
The connecting rod cap is held by bolts tightened to plastic region. 171EG07 5. Crankshaft
The crankshaft has 5 journals and 4 balance weights.
A crankshaft position sensor rotor has been pressed into the crankshaft to realize an integrated configuration.
The surface roughness of the pins and journals have been improved for low-friction operation.
The bearing width has been reduced for low-friction operation. Crankshaft Position Sensor Rotor Oil Hole Pin No.5 Journal No.1 Journal Balance Weight 182EG07 49 ENGINE – 1NZ-FXE ENGINE VALVE MECHANISM 1. General  Each cylinder has 2 intake valves and 2 exhaust valves.  The valves are directly opened and closed by 2 camshafts.  The intake and exhaust camshafts are driven by a roller timing chain.  The VVT-i system is used to improve fuel economy, engine performance and reduce exhaust emission. Exhaust Camshaft Timing Chain VVT-i Controller Intake Camshaft Chain Tensioner Chain Tension Arm Chain Guide 171EG09 2. Camshafts  In conjunction with the adoption of the VVT-i system, an oil passage is provided in the intake camshaft in order to supply engine oil to the VVT-i system.  A VVT-i controller has been installed on the front of the intake camshaft to vary the timing of the intake valves.  The timing rotor is provided behind the intake camshaft to trigger the camshaft position sensor. Exhaust Camshaft Timing Rotor Intake Camshaft VVT-i Controller 171EG10 50 ENGINE – 1NZ-FXE ENGINE 3. Intake and Exhaust Valve and Valve Lifter  Valve lifters with shimless valve adjustment have been adopted for weight reduction. The adjustment of the valve clearance is accomplished by selecting and replacing the appropriate valve lifters.  Narrower valve stems have been adopted to reduce the intake and exhaust resistance and for weight reduction.
Specifications  mm (in.) Intake Valve Exhaust Valve Face Diameter 30.5 (1.2) 25.5 (1.0) Stem Diameter 5.0 (0.20) 5.0 (0.20) Item Camshaft Valve Lifter Valve 165EG12 4. Timing Chain  A roller timing chain with an 8.0 mm pitch has been adopted to make the engine more compact and reduce chain noise. Camshaft Sprockets Timing Chain  A material which has excellent wear resistance has been selected for the timing chain to improve reliability.  The timing chain is lubricated by engine oil from an oil jet.  Chain tensioner, chain tension arm and chain guide are established to reduce the engine noise and friction loss. Chain Tensioner Chain Guide Chain Tension Arm Oil Jet Crankshaft Sprocket 171EG12 51 ENGINE – 1NZ-FXE ENGINE 5. Chain Tensioner  The chain tensioner uses a spring and oil pressure to maintain proper chain tension at all times. The chain tensioner suppresses noise generated by the chain. Spring Plunger  A ratchet type half-back mechanism is used. Check Ball Cam Cam Spring 171EG13 6. Timing Chain Cover  A single-piece, aluminum die-cast timing chain cover that entirely seals the front portion of the cylinder block and the cylinder head has been adopted.  A service hole for the chain tensioner has been provided in the timing chain cover to improve serviceability. Service Hole for Chain Tensioner Oil Pump Back View Front View 171EG31 171EG32 52 ENGINE – 1NZ-FXE ENGINE LUBRICATION SYSTEM
The lubrication circuit is fully pressurized and all oil passes through an oil filter.
A trochoid gear type oil pump, which is driven directly by the crankshaft, has been provided in the front of the cylinder block.
The oil filter has been installed diagonally downward from the side of the cylinder block to improve serviceability. 182EG08 MAIN OIL HOLE RELIEF VALVE CRANKSHAFT JOURNAL CYLINDER HEAD OIL JET OIL FILTER RELIEF VALVE CAMSHAFT TIMING OIL CONTROL VALVE FILTER CONNECTING ROD CHAIN TENSIONER INTAKE CAMSHAFT JOURNAL OIL PUMP OIL JET TIMING CHAIN OIL STRAINER EXHAUST CAMSHAFT JOURNAL CAMSHAFT TIMING OIL CONTROL VALVE PISTON VVT-i OIL PAN 182EG09 53 ENGINE – 1NZ-FXE ENGINE COOLING SYSTEM 1. General
The cooling system is a pressurized, forced-circulation type.
A thermostat with a bypass valve is located on the water inlet housing to maintain suitable temperature distribution in the cooling system.
The flow of the engine coolant makes a U-turn in the cylinder block to ensure a smooth flow of the engine coolant.
The radiator for the engine and the A/C condenser have been integrated to minimize the space they occupy in the engine compartment. From Heater To Heater To Radiator Water Pump From Radiator 182EG10 Cylinder Head Heater Core Bypass Passage Cylinder Block Water Pump Thermostat Radiator Throttle Body 171EG17 54 ENGINE – 1NZ-FXE ENGINE 2. Radiator The radiator for the engine and the A/C condenser have been integrated to minimize the space they occupy in the engine compartment. Cutouts have been provided between the radiator and condenser sections to prevent the transfer of heat between the two sections. Condensor Radiator Condensor Radiator Cutout 182EG11 55 ENGINE – 1NZ-FXE ENGINE INTAKE AND EXHAUST SYSTEM 1. Throttle Body
The adoption of the ETCS-i has realized excellent throttle control.
The ISC system and cruise control system are controlled comprehensively by the ETCS-i.
The ETCS-i, which drives the throttle valve through a DC motor that is controlled by the ECM, thus doing away with a throttle link to connect the accelerator pedal to the throttle valve, has been adopted.
The throttle control motor is provided with a return spring that closes the throttle valve.
An opener spring is provided on the throttle position sensor side. This spring opens the throttle valve slightly when the engine is stopped to prevent the throttle valve from sticking and to improve the engine’s restartability.
A warm coolant passage is provided below the throttle body to prevent the throttle valve from freezing during cold temperatures. Throttle Control Motor A Return Spring A Opener Spring Throttle Position Sensor A – A Cross Section 182EG12 2. Intake Manifold
Because it is not necessary to improve the intake air efficiency through inertial intake due to the adoption of the Atkinson cycle, the length of the intake pipe of the intake manifold has been shortened, and furthermore, the intake pipes for cylinders #1 and #2, as well as for #3 and #4, have been integrated midstream to achieve a large-scale weight reduction. In addition, the throttle body has been oriented downflow in the center of the surge tank to achieve a uniform intake air distribution. Vacuum Port
A vacuum port has been provided for the Toyota HC adsorber and catalyst system. 182EG13 56 ENGINE – 1NZ-FXE ENGINE 3. Exhaust Manifold
A ball joint has been adopted for coupling the exhaust manifold to the front pipe in order to improve reliability.
A stainless steel exhaust manifold is used for weight reduction. 182EG14 4. Muffler General
A ball joint has been adopted for coupling the exhaust manifold to the exhaust pipe and the exhaust pipe to the main muffler to achieve a simple configuration and improved reliability.
The ceramic walls in the front TWC (Three-Way Catalytic Converter) have been decreased in thickness and increased in density from the conventional models. By decreasing the thermal capacity in this manner, it becomes easier to heat the catalyst and the catalyst’s exhaust cleansing performance is improved.
A Toyota HCAC (HC Adsorber and Catalyst) system has been adopted to improve the clean emission performance of the exhaust gases when the temperature of the TWC is low. Ball Joints TWC Main Mufflar TWC with HC Adsorber 182EG15 Toyota HCAC System a) General This system provides HC adsorber coaxially to the TWC to improve the clean emission performance of the exhaust gases when the temperature of the TWC is low. b) Construction This system consists of HC adsorber, TWC, actuator, bypass valve. Actuator Bypass Valve HC Adsorber TWC 182EG16 57 ENGINE – 1NZ-FXE ENGINE c) Operation Before the engine is started, the bypass valve remains open. When the engine is started, the ECM outputs a signal to the VSV (for HC adsorber and catalyst system), which is applying a vacuum to the actuator. As a result, the bypass valve closes. Immediately after the engine has started, the exhaust gases pass through the HC adsorber in which HC adsorbed and stored for a certain time (until the temperature of the HC adsorber rises). And prevent the HC emitted from the tail pipe when the temperature of the TWCs are low. After the TWC has warmed up, the VSV closes to the bypass valve to open. Then, as the temperature of the rear TWC rises, the temperature of the HC absorber that surrounds it also rises, and the HC starts to be desorbed, and cleaned by the TWC. Furthermore, this system activates the VSV after the HC adsorber is warmed up and triggerd by deceleration condition, the bypass valve is closed in order to scavenge the HC that remains in the HC adsorber. Exhaust Gas Cold Engine or Scavenging Mode 182EG17 Warm Engine 182EG18 58 ENGINE – 1NZ-FXE ENGINE FUEL SYSTEM 1. Injector A compact 12-hole type injector has been adopted to improve the atomization of fuel. 2. Fuel Returnless System This system is to reduce the evaporative emission. As shown below, integrating the pressure regulator and fuel filter with the fuel pump assembly made it possible to discontinue the return of fuel from the engine area and prevent temperature rise inside the fuel tank. Injector Delivery Pipe Pressure Regulator Fuel Filter Fuel Tank Fuel Pump 182EG38 3. Quick Connector Quick connector has been adopted to connect the fuel pipe with the fuel hose to improve serviceability. 59 ENGINE – 1NZ-FXE ENGINE 4. ORVR System The ORVR (On-Board Refueling Vapor Recovery) is a system that uses a charcoal canister, which is provided onboard, to recover the fuel vapor that is generated during refueling. This reduces the discharge of fuel vapor into the atmosphere. Air Cleaner Intake Air Chamber : Vapor : Fuel VSV (for EVAP) ECM VSV (for Purge Flow Switching Valve) Fuel Charcoal Canister Fuel Inlet Pipe Vapor Pressure Sensor VSV (for Canister Closed Valve) 182EG19 5. Fuel Tank General  To reduce the amount of fuel vapor generated when the vehicle is parked, during refueling, or while driving, a vapor reducing fuel tank system has been adopted. This system provides a vapor reducing fuel tank that expands or contracts in accordance with the volume of the fuel in the fuel storage area in the fuel tank. By thus reducing the space in which fuel can evaporate, the generation of fuel vapor is minimized.  Along with the provision of the vapor reducing fuel tank whose size fluctuates in the fuel tank, the fuel gauge and the fuel pump have been provided in the sub tank. For this reason, a direct-acting fuel gauge has been adopted. NOTE: At low ambient temperatures, the capacity of the vapor reducing fuel tank is reduced as it is made of resin (When the outside temperature is at –10C (14F) the size of the tank will be reduced by approximate 5 liters). 60 ENGINE – 1NZ-FXE ENGINE
System Diagram  From Air Cleaner To Intake Air Chamber When the Tank is Full Vapor Reducing Fuel Tank 182EG20 From Air Cleaner To Intake Air Chamber When the Tank is Empty 182EG21 Fuel Gauge  A direct-acting fuel gauge has been provided in the sub tank.  This gauge consists of a pipe that is surrounded by a coil, and a float in the pipe moves up and down with the fluctuation of the fuel level. A magnet is attached to the back side of the float. The up or down movement of the float causes a change in the magnetic field. The flow of current through the coil creates a potential difference, and the resultant voltage is transmitted to the meter ECU. For details, see page 146 (Meter Section). 61 ENGINE – 1NZ-FXE ENGINE
IGNITION SYSTEM 1. General A DIS (Direct Ignition System) has been adopted. The DIS improves the ignition timing accuracy, reduces high-voltage loss, and enhances the overall reliability of the ignition system by eliminating the distributor. The DIS in 1NZ-FXE engine is an independent ignition system which has one ignition coil (with igniter) for each cylinder. ECM Camshaft Position Sensor Crankshaft Position Sensor Various Sensors G2 +B Ignition Coil (with Igniter) IGT1 No.1 Cylinder IGT2 No.2 Cylinder IGT3 No.3 Cylinder IGT4 No.4 Cylinder NE IGF 165EG25 2. Ignition Coil The DIS provides 4 ignition coils, one for each cylinder. The spark plug caps, which provide contact to the spark plugs, are integrated with an ignition coil. Also, an igniter is enclosed to simplify the system. 3. Spark Plug Iridium-tipped spark plugs have been adopted to realize a 60,000-mile (100,000 km) maintenance-free operation. Their center electrode is made of iridium, which excels in wear resistance. As a result, the center electrode is made with a smaller diameter and improved the ignition performance.
CHARGING AND STARTING SYSTEM MG1 and MG2 (Motor Generator No.1 and 2) have been adopted in the charging system, and the conventional generator has been discontinued. Furthermore, due to the adoption of MG1 for the starting system, the conventional starter has been discontinued. 62 ENGINE – 1NZ-FXE ENGINE ENGINE CONTROL SYSTEM 1. General The engine control system for the 1NZ-FXE engine has following system. System Outline SFI Sequential Multiport Fuel Injection An L-type SFI system directly detects the intake air volume with a hot-wire type mass air flow meter. ESA Electronic Spark Advance Ignition timing is determined by the ECM based on signals from various sensors. The ECM corrects ignition timing in response to engine knocking. VVT-i Variable Valve Timing-intelligent Controls the intake camshaft to an optimal valve timing in accordance with the engine condition. ETCS-i Electronic Throttle Control System-intelligent Optimally controls the throttle valve opening in accordance with the ECM, and the conditions of the engine and the vehicle, and comprehensively controls the ISC and cruise control system. Fuel Pump Control
Fuel pump operation is controlled by signal from the ECM.
To stop the fuel pump during operation of the SRS airbag. Oxygen Sensor Heater Control Maintains the temperature of the oxygen sensors at an appropriate level to increase accuracy of detection of the oxygen concentration in the exhaust gas. Evaporative Emission Control
The ECM controls the purge flow of evaporative emissions (HC) in the charcoal canister in accordance with engine conditions.
Using 3 VSVs and a vapor pressure sensor, the ECM detects any evaporative emission leakage occurring between the fuel tank and the charcoal canister, and vapor reducing fuel tank through the changes in the tank pressure. For details, see page 79. Toyota HCAC System The ECM controls the VSV (for Toyota HCAC System) to improve the clean emission performance of the exhaust gas when the temperature of the TWC is low. For details, see page 58. Air Conditioning Cut-Off Control By turning the air conditioning compressor OFF in accordance with the engine condition, drivability is maintained. Cooling Fan Control Radiator cooling fan operation is controlled by signals from ECM based on the engine coolant temperature sensor signal (THW). HV Immobiliser Prohibits fuel delivery, ignition, and starting the HV system if an attempt is made to start the HV system with an invalid ignition key. For details, see page 80. Diagnosis When the ECM detects a malfunction, the ECM diagnoses and memorizes the failed section. Fail-Safe When the ECM detects a malfunction, the ECM stops or controls the engine according to the data already stored in memory. 63 ENGINE – 1NZ-FXE ENGINE 2. Construction The configuration of the engine control system in the INZ-FXE engine is shown in the following chart. SENSORS MASS AIR FLOW METER ACTUATORS VG SFI #10 CRANKSHAFT POSITION SENSOR #20 NE #30 #40 CAMSHAFT POSITION SENSOR THROTTLE POSITION SENSOR G2 VTA VTA2 ENGINE COOLANT TEMP. SENSOR THW INTAKE AIR TEMP. SENSOR THA IGT1
IGT4 IGF No.1 INJECTOR No.2 INJECTOR No.3 INJECTOR No.4 INJECTOR ESA IGNITION COIL with IGNITER SPARK PLUGS VVT-i OCV IGNITION SWITCH COMBINATION METER IGSW ECM SPD
Vehicle Speed Signal HEATED OXYGEN SENSOR (Bank 1, Sensor 1) CAMSHAFT TIMING OIL CONTROL VALVE ETCS-i M THROTTLE CONTROL MOTOR OX1A FUEL PUMP CONTROL FC HEATED OXYGEN SENSOR (Bank 1, Sensor 2) OX1B KNOCK SENSOR KNK1 OIL PRESSURE SWITCH OXYGEN SENSOR HEATER CONTROL HEATED OXYGEN SENSOR HEATER MOPS HT1A HT1B AMBIENT TEMP. SENSOR TAM CIRCUIT OPENING RELAY Bank 1, Sensor 1 Bank 1, Sensor 2 (Continued) 64 ENGINE – 1NZ-FXE ENGINE MPX1 HTE ETH HV ECU (Hybrid Vehicle Control ECU) NEO SPHV ESTP METER ECU AIR CONDITIONING ECU DISPLAY ECU GO MPX2 BODY ECU VPA 1, 2 ACCELERATOR PEDAL POSITION SENSOR AIR CONDITIONING CUTOFF CONTROL ACT AIR CONDITIONING ECU EVAP CONTROL EVP1 CCV VACUUM SENSOR (for TOYOTA HCAC SYSTEM) HCLS ECM TBP VSV (for EVAP) VSV (for CANISTER CLOSED VALVE) VSV (for PURGE FLOW SWITCHING VALVE) COOLING FAN CONTROL FAN VAPOR PRESSURE SENSOR PTNK HCC MREL DATA LINK CONNECTOR 3 COOLING FAN RELAY SIL TC +B EFI MAIN RELAY W BATT, BM BATTERY VSV (for TOYOTA HCAC SYSTEM) EFI MAIN RELAY MALFUNCTION INDICATOR LAMP 65 ENGINE – 1NZ-FXE ENGINE 3. Engine Control System Diagram VSV (for EVAP) HV ECU ECM Mass Air Flow Meter Intake Air Temp. Sensor Throttle Position Sensor Accelerator Pedal Position Sensor Cooling Fan Relay Circuit Opening Relay Heated Oxygen Sensor (Bank 1, Sensor 1) Igniter Camshaft Timing Oil Control Valve Throttle Control Injector Motor Engine Coolant Temp. Sensor Camshaft Position Sensor VSV (for Toyota HCAC System) Vacuum Sensor (for Toyota HCAC System) Knock Sensor TWC Actuator (for HC Adsorber) Crankshaft Position Sensor VSV (for Purge Flow Switching Valve) Charcoal Canister Heated Oxygen Sensor (Bank 1, Sensor 2) TWC (with HC Adsorber) Vapor Pressure Sensor VSV (for Canister Closed Valve) Fuel Pump 182EG22 66 ENGINE – 1NZ-FXE ENGINE 4. Layout of Components VSV (for Purge Flow Switching Valve) Oil Control Valve Ignition Coil with Igniter ECM Charcoal Canister VSV (for EVAP) Vapor Pressure Sensor VSV (for TOYOTA HCAC System) Mass Air Flow Meter Throttle Control Motor Knock Sensor DLC 3 Crankshaft Position Sensor Trap Filter VSV (for Canister Closed Valve) Heated Oxygen Sensor (Bank 1, Sensor 2) Camshaft Position Sensor Engien Coolant Temp. Sensor Heated Oxygen Sensor (Bank 1, Sensor 1) Injector 182EG23 67 ENGINE – 1NZ-FXE ENGINE 5. Main Components of Engine Control System The main components of the 1NZ-FXE engine control system are as follows: Components Outline Quantity Hot-Wire Type 1 Crankshaft Position Sensor (Rotor’s Teeth) Pick-Up Coil Type (36-2) 1 Camshaft Position Sensor (Rotor’s Teeth) Pick-Up Coil Type (3) 1 Throttle Position Sensor Linear Type (Double) 1 Knock Sensor Built-In Piezoelectric Element Type 1 Oxygen Sensor Heated Oxygen Sensor (Bank 1, Sensor 1) (Bank 1, Sensor 2) 2 12-Hole Type 4 Mass Air Flow Meter Injector 6. VVT-i (Variable Valve Timing-intelligent) System General The VVT-i system is designed to control the intake camshaft within a wide range of 43 (of crankshaft angle) to provide a valve timing that is optimally suited to the engine condition, thus realizing improved torque in all the speed ranges and fuel economy, and reduce exhaust emissions. VVT-i Controller ECM Camshaft Position Sensor Crankshaft Position Sensor Camshaft Timing Oil Control Valve 182EG24 68 ENGINE – 1NZ-FXE ENGINE Construction 1) VVT-i Controller This controller consists of the housing driven from the timing chain and the vane coupled with the intake camshaft. The oil pressure sent from the advance or retard side path at the intake camshaft causes rotation in the VVT-i controller vane circumferential direction to vary the intake valve timing continuously. Vane (Fixed on Intake Camshaft) Intake Camshaft Housing 182EG40 2) Camshaft Timing Oil Control Valve To VVT-i Controller The camshaft timing oil control valve controls (Advanced Side) (Retard Side) the spool valve position in accordance with Spool Valve Sleeve the duty control from the ECM thus allocating the hydraulic pressure that is applied to the VVT-i controller to the advance and the retard side. When the engine is stopped, the camshaft timing oil control valve is in the most reSpring tarded state. Drain Drain Coil Oil Pressure Plunger 165EG34 69 ENGINE – 1NZ-FXE ENGINE Operation The camshaft timing oil control valve selects the path to the VVT-i controller according to the advance, retard or hold signal from the ECM. The VVT-i controller rotates the intake camshaft in the timing advance or retard position or holds it according to the position where the oil pressure is applied. 1) Advance When the camshaft timing oil control valve is positioned as illustrated below by the advance signal from the ECM, the resultant oil pressure is applied to the timing advance side vane chamber to rotate the camshaft in the timing advance direction. VVT-i Controller Housing ECM Vane Rotating Direction Oil Pressure 185EG18 2) Retard When the camshaft timing oil control valve is positioned as illustrated below by the retard signal from the ECM, the resultant oil pressure is applied to the timing retard side vane chamber to rotate the camshaft in the timing retard direction. ECM Rotating Direction Oil Pressure 185EG19 70 ENGINE – 1NZ-FXE ENGINE 3) Hold The ECM calculates the target timing angle according to the traveling state to perform control as described in the previous page. After setting at the target timing, the valve timing is held by keeping the camshaft timing oil control valve in the neutral position unless the traveling state changes. This adjusts the valve timing at the desired target position and prevents the engine oil from running out when it is unnecessary. ECM Oil Pressure 185EG10 71 ENGINE – 1NZ-FXE ENGINE In proportion to the engine speed, intake air volume, throttle position and water temperature, the ECM calculates an optimal valve timing under each driving condition and control the camshaft timing oil control valve. In addition, ECM uses signal from the camshaft position sensor and the crankshaft position sensor to detect the actual valve timing, thus performing feedback control to achieve the target valve timing.
Operation During Various Driving Condition (Conceptual Diagram)  Full Load Performance Engine Load Range 5 Range 4 Range 3 Range 2 Range 1 Engine Speed 182EG25 Operation State Range During Idling 1 Valve Timing TDC Latest timing IN EX BDC Objective Effect Eliminating overlap to reduce blow back to the intake side Stabilized idling rpm Better fuel economy Decreasing overlap to eliminate blow back to the intake side Ensured engine stability Increasing overlap to increase internal EGR for pumping loss elimination Better fuel economy Improved emission control 182EG26 To retard side At Light Load 2 EX IN 182EG27 To advance side At Medium load 3 EX IN 182EG28 72 ENGINE – 1NZ-FXE ENGINE Operation State Range In Low to Medium Speed Range with Heavy Load In High Speed Range with Heavy Load Valve Timing TDC EX IN 4 To advance side EX BDC IN — EX Advancing the intake valve close timing for volumetric efficiency improvement Improved torque in low to medium speed range Retarding the intake valve close timing for volumetric efficiency improvement Improved output Eliminating overlap to prevent blow back to the intake side for reduction of fuel increase at low temperatures, and stabilizing the idling rpm for decreasing fast idle rotation Stabilized fast idle rpm Better fuel economy Eliminating overlap to eliminate blow back to the intake side Improved startability 182EG30 Latest timing At Low Temperatures Effect 182EG29 5 To retard side Objective IN 182EG26 Latest timing Upon Starting/ Stopping the Engine — EX IN 182EG26 73 ENGINE – 1NZ-FXE ENGINE 7. Fuel Pump Control A fuel cut control is adopted to stop the fuel pump when the SRS airbag is deployed, thus helping reduce fuel leakage. In this system, the airbag deployment signal from the airbag sensor assembly is detected by the HV ECU, send the signal to ECM, which turns OFF the circuit opening relay. After the fuel cut control has been activated, turning the ignition switch from OFF to ON cancels the fuel cut control, thus engine can be restarted. Front Airbag Sensors (RH and LH) Airbag Sensor Assembly HV ECU ECM Circuit Opening Relay Fuel Pump Motor 182EG39 74 ENGINE – 1NZ-FXE ENGINE 8. ETCS-i (Electronic Throttle Control System-intelligent) General  The ETCS-i, which realizes excellent throttle control in all the operating ranges, has been adopted.  In the conventional throttle body, the throttle valve opening is determined invariably by the amount of the accelerator pedal effort. In contrast, the ETCS-i used the ECM to calculate the optimal throttle valve opening that is appropriate for the respective driving condition and uses a throttle control motor to control the opening.  The ETCS-i controls the ISC (Idle Speed Control) system and the cruise control system.
System Diagram  Throttle Valve Accelerator Pedal Position Sensor Throttle Position Sensor Throttle Control Motor HV ECU ECM 182EG31 Construction 1) Accelerator Pedal Position Sensor The accelerator pedal position sensor is mounted on the accelerator pedal. To detect the pedal opening angle, 2 separate systems consisting of main and sub sensors are used, and 2 separate return springs are used to improve reliability. In the detecting portions, Hall elements have been adopted. Due to the characteristics of the Hall elements, different signals are output depending on whether the pedal is pressed all the way or is released. To correct these signals, a mechanical device has been provided to detect the correct pedal opening angle. The sensors of the 2 systems output the same signals. Output Voltage (V) Accelerator Pedal Position Sensor 5.0 VPA2 4.0 3.0 2.0 VPA1 1.0 0 10 20 30 40 50 60 70 80 125 Accelerator Pedal Depressed Angle 182EG32 182EG33 75 ENGINE – 1NZ-FXE ENGINE 2) Throttle Position Sensor The throttle position sensor is mounted on the throttle body. The throttle position sensor converts the amount of accelerator pedal effort into two types of electrical signals with distinct output characteristics. The signals are then input into the ECM. V Open VC VTA1 VTA2 Output Voltage 5 Close VTA2 VTA1 Open 0 Close Accelerator Pedal Depressed Angle E2 150EG40 150EG39 3) Throttle Control Motor A DC motor with excellent response and minimal power consumption is used for the throttle control motor. The ECM performs the duty ratio control of the direction and the amperage of the current that flows to the throttle control motor in order to regulate the opening angle of the throttle valve. Operation The ECM drives the throttle control motor by determining the target throttle valve opening in accordance with the respective operating condition. 1) Idle Speed Control The idle speed control is effected entirely by the ETCS-i. The following are the contents of the control: idle-up control during cold engine operation, intake air volume control to improve the startability of the engine, and control for when the electrical load changes such as when the air conditioning switch is turned ON or OFF. 2) Cruise Control Through the adoption of the ETCS-i, the vehicle speed is now controlled by the throttle control motor, which controls the throttle valve. 76 ENGINE – 1NZ-FXE ENGINE Fail Safe If an abnormal condition occurs with the ETCS-i, the check engine warning light in the combination meter illuminates to alert the driver. The current to the throttle control motor is cut off to prevent the ETCS-i from operating. This enables the return spring to close the throttle valve. Diagnosis If the diagnostic trouble code 89 is being output to the combination meter check engine warning light, it means that the ECM has detected a malfunction in the ETCS-i, and outputs the diagnostic trouble code of the ETCS-i. Also, the diagnostic trouble code can be output to a hand-held tester via the data link connector 3. For details, refer to the 2001 Prius Repair Manual (Pub. No.RM778U). 77 ENGINE – 1NZ-FXE ENGINE 9. Evaporative Emission Control General A vacuum system has been newly adopted to detect leaks in the evaporative emission control system. This vacuum system detects leaks by forcefully introducing the purge vacuum into the entire system and monitoring the changes in the pressure. In order to detect evaporative emission leaks from the vapor reducing fuel tank, a density method has been adopted. This system uses an oxygen sensor to measure the HC density in the exhaust gases in order to detect leaks. It consists of the following main conponents:
A VSV (for canister closed valve) has been provided between the fresh air line and the fuel tank.
The VSV (for purge flow switching valve) switches the passages from the charcoal canister to the purge line and from the fuel tank to the purge line.
A vapor pressure sensor has been provided in the fuel tank in order to further ensure the precision of the vapor pressure sensor.
DTCs (Diagnostic Trouble Codes) have been added. For details on the DTCs (Diagnostic Trouble Codes), refer to the 2001 Prius Repair Manual (Pub. No.RM778U). Air Cleaner Intake Air Chamber VSV (for EVAP) ECM VSV (for Purge Flow Switching Valve) Fresh Air Line Purge Line EVAP Line Recircle Line Charcoal Canister Vapor Pressure Sensor VSV (for Canister Closed Valve) 182EG34 78 ENGINE – 1NZ-FXE ENGINE Operation Initially, the VSV (for canister closed valve) is closed, and the VSV (for EVAP) is open, enabling the VSV (for purge flow switching valve) to keep the passage between the charcoal canister and the purge line open. This causes a vacuum to be applied to the purge line, evaporator line, recirculation line, and the line from the charcoal canister to the fuel tank. Next, the VSV (for EVAP) is closed in order to maintain a vacuum from the VSV (for EVAP) to the inside of the fuel tank. Then, any subsequent changes in the pressure are monitored by the vapor pressure sensor in order to check for evaporative emission leaks. Next, the VSV (for canister closed valve) and the VSV (for EVAP) open, enabling the VSV (for purge flow switching valve) to keep the passage between the fuel tank and the purge line open. Then, the air in the fuel tank is drawn in by the vacuum of the intake chamber, and the density of HC in the exhaust gases is measured by the oxygen sensor to detect any leaks. If a leak is detected, the malfunction indicator lamp (MIL) illuminates to inform the driver. Also, the diagnostic trouble code (DTC) can be accessed through the use of a hand-held tester. For details on the DTCs, refer to the 2001 Prius Repair Manual (Pub. No.RM778U). 10. HV Immobiliser System The HV immobiliser system has been designed to prevent the vehicle from being stolen. This system uses a HV ECU that stores the ID code of the authorized ignition key. If an attempt is made to start the HV system using an unauthorized key, the HV ECU prohibit fuel delivery, ignition, and starting the HD system effectively disabling the engine. For details see page 184 in the HV Immobiliser System section. 11. Diagnosis System The diagnostic trouble codes can be output via DLC3 to an OBD-II scan tool or a hand-held tester. For details, refer to the 2001 Prius Repair Manual (Pub. No.RM778U). 22 THS (TOYOTA HYBRID SYSTEM) THS (TOYOTA HYBRID SYSTEM)
DESCRIPTION The hybrid system is a type of powertrain that uses a combination of two types of motive forces, such as an engine and a motor (MG2). This system is characterized by its skillful use of two types of motive forces according to the driving conditions. It maximizes the strengths of each of the motive forces and complements their weaknesses. Thus, it can achieve a highly responsive, dynamic performance, as well as a dramatic reduction in fuel consumption and exhaust gas emissions. The THS can be broadly divided into two systems: the series hybrid system, and the parallel hybrid system. MG1 Planetary Gear Unit HV Battery Inverter Engine MG2 Differential Gear Unit Hybrid Transaxle Mechanical Power Path Electrical Path 182TH03 – REFERENCE – Series Hybrid System In the series hybrid system, the engine runs a generator, and the generated electricity enables the electric motor to drive the wheels. This type of vehicle can be described as an electric car that is equipped with an engine-driven generator. Equipped with a low-output engine, the engine is operated at a practically constant speed in its most effective range, in order to efficiently recharge the battery while the vehicle is in motion. Battery *1 Inverter *2 Engine Generator Electric Motor *1: *2: Direct Current Alternating Current Parallel Hybrid System This system uses both the engine and the electric motor to directly drive the wheels is called the parallel hybrid system. In addition to supplementing the motive force of the engine, the electric motor in this system can also serve as a generator to recharge the battery while the vehicle is in motion. 182TH01 Battery Inverter Engine Transmission Motor/Generator 182TH02 23 THS (TOYOTA HYBRID SYSTEM)
FEATURES OF THS This system controls the following modes in order to achieve the most efficient operations to match the driving conditions: 1. Supply of electrical power from the HV battery to MG2 provides force to drive the wheels 2. While the tires are driven by the engine via the planetary gears, MG1 is driven via the planetary gears to supply electricity to MG2 to drive the wheels 3. When the vehicle is decelerating, kinetic energy from the wheels is recovered and converted into electrical energy and used to recharge the HV battery by means of MG2. The HV ECU switches between these modes (1, 2, 1 + 2, or 3) according to the driving conditions. However, when the SOC of the HV battery is low, the HV battery is charged by the engine by turning MG1. As a result, it achieves far greater the fuel economy compared to conventional gasoline engine vehicles, at a reduced level of exhaust gas emissions. Furthermore, this revolutionary powertrain has eliminated the constraints that are associated with electric vehicles (such as their short cruising range or their reliance on external recharging units).
LAYOUT OF MAIN COMPONENTS HV ECU Shift Position Sensor ECM Brake ECU Engine HV Battery Inverter with Converter Hybrid Transaxle Accelerator Pedal Position Sensor Battery ECU SMR (System Main Relay) Service Plug 182TH19 24 THS (TOYOTA HYBRID SYSTEM)
MAIN FUNCTIONS OF COMPONENTS Hybrid Transaxle MG1 Generates high-voltage electricity by being powered primarily by the engine. Also functions as a starter to start the engine. MG2 Primarily provide additional power to the engine in order to increase the overall drive force. During braking, or when the accelerator pedal is not depressed, it generates electricity to recharge the HV battery (Regenerative brake system). Planetary Gear Unit Distributes the engine’s drive force as appropriate to directly drive the vehicle as well as the generator. HV Battery Supplies electric power to the MG2 during start-off, acceleration, and uphill driving; recharged during braking or when the accelerator pedal is not depressed. Inverter A device that converts the high-voltage DC (HV battery) into AC (MG1 and MG2) and vice versa (Converts AC into DC). Converter Drops the high-voltage direct current (DC 273.6 V) into DC12 V in order to supply electricity to body electrical components, as well as to recharge the auxiliary battery (12 V). HV (Hybrid Vehicle Control) ECU Information from each sensor as well as from the ECU (ECM, Battery ECU, ABS ECU) is received, and based on this the required torque and output power is calculated. The HV ECU sends the calculated result to the actuators and controllers. ECM Sends a throttle open command to the electronically-controlled throttle in accordance with the engine output request factor received from the HV ECU. Battery ECU Monitors the charging condition of the HV battery. Brake ECU Controls the regenerative brake that is effected by the MG2 and the hydraulic brake so that the total braking force equals that of a conventional vehicle that is equipped only with hydraulic brakes. Also, the brake ECU performs the ABS control conventionally. Accelerator Pedal Position Sensor Shift Position Sensor Converts the accelerator angle into an electrical signal and outputs it to the HV ECU. Converts the shift lever position into an electrical signal and outputs it to the HV ECU. SMR (System Main Relay) Connects and disconnects the high-voltage power circuit through the use of a signal from the HV ECU. Service plug Shuts off the high-voltage circuit of the HV battery when this plug is removed for vehicle inspection or maintenance. 25 THS (TOYOTA HYBRID SYSTEM)
SYSTEM DIAGRAM Shift Position Sensor Shift Position (Main and Sub) Accelerator Angle (Main and Sub) Accelerator Pedal Position Sensor Regenerative Request Factor BRAKE ECU Inverter HV ECU Actual Regenerative Braking Factor RPM SMR Control Engine Power Request Hydraulic Brake Charging Condition, Amperage SMR SMR Amperage Wheel MG2 Wheel Voltage ECM MG1 Planetary Gear Unit Converter Engine Battery ECU HV Battery Auxiliary Battery 182TH05 Mechanical Power Path Hydraulic Electrical Signal 26 THS (TOYOTA HYBRID SYSTEM) DRIVING CHARACTERISTICS Because the Prius uses a parallel series hybrid system, some aspects of its operation may differ from those of existing automobiles, and may require precautions that are unique to this system. 1. Starting the THS Make sure that the parking brake is engaged and that the shift lever is in the P position. While depressing the brake pedal, turn the ignition switch to the START position. After this, the “READY” light flashes. The engine does not start when the shift lever is in the N position; it can only start in the P position. When the external air temperature is low, the “READY” light may flash longer than usual. As soon as the engine has started, the “READY” light illuminates steadily and a beeping sound is heard. Several seconds after the engine warms up, the engine stops automatically, provided that the air conditioning compressor does not need to operate and that the HV battery maintains a proper SOC (state of charge). Output Control “READY” Light Warning Light While keeping the brake pedal depressed, release the parking brake, and move the shift lever to the D position. The vehicle has the same creeping movement as the conventional automatic transmission vehicles. Gradually release the brake pedal and slowly depress the accelerator pedal to start off. At this time, the vehicle starts off powered only by the MG2 (Motor Generator No.2) 182TH24 NOTICE: The vehicle can be started off, provided that the “READY” light remains illuminated, even if the engine remains stopped. 2. Start-Off 3. Acceleration Depress the accelerator pedal to accelerate the vehicle. If the engine remained stopped during start-off, the engine will start automatically during acceleration. 4. Downhill Driving Move the shift lever to the B position as necessary in order to simultaneously apply the regenerative brake and the engine friction brake. 5. Deceleration and Stopping Depress the brake pedal to decelerate and to stop the vehicle. Depressing the brake pedal causes the regenerative brake to activate automatically in the D or B position. (In the regenerative brake system, kinetic energy is converted to electrical energy.) If the engine has warmed up, the air conditioning compressor does not need to operate, and if the HV battery maintains a proper SOC (state of charge), the engine stops automatically when the vehicle speed drops-even if the vehicle comes to a stop. 6. Parking Push down the parking brake pedal, move the shift lever to the P position, and pull out the ignition key. NOTICE: Make sure to pull out the ignition key after parking the vehicle because the vehicle can be driven as long as the “READY” light remains illuminated even if the engine is stopped. 7. Other Characteristics and Precautions
If a drive wheel slips on slippery terrain, causing the front wheels to spin faster than the rear wheels, the THS effects control to limit the slippage by restraining the drive force. (This also protects the planetary gear from damage.)
When the HV battery temperature is too high or low, the output control warning light illuminates, alerting the driver that output power may be limited. This is not 2 malfunction. This condition may be corrected by avoiding sudden acceleration/decelaration, after which the light will go out.
When the vehicle is stopped and the shift lever is in the N position, electricity is not generated even if the engine is running. If the vehicle remains stopped for a long time, make sure to move the shift lever to the P position. In heavy traffic, keep the shift lever in the D position. THS (TOYOTA HYBRID SYSTEM) 27 THS CONTROL SYSTEM 1. General The THS control system contains the following components: HV (Hybrid Vehicle Control) ECU Controls the MG1, 2 and the engine according to the demand torque, regenerative brake control and the SOC (state of charge) of HV battery. These factors are determined by the shift position, the degree which the accelerator is depressed, and vehicle speed. ECM Control The HV ECU receives engine status data (rpm, torque) from the ECM and determines the engine demand torque. Moreover, engine stop and fuel cut signals are sent according to the driving conditions. In addition, the vehicle speed signal received from the combination meter is also sent. BRAKE ECU Control The HV ECU receives data corresponding to the total braking force needed. The HV ECU transmits the regeneration brake demand torque valve, as well as the regeneration brake execution torque valve. Inverter (for MG1, MG2) Control The HV ECU sends the signal to the power transistor in the inverter for switching the U, V, W, phase of the MG1, 2 in order to drive the MG1 and 2. Moreover, if an overheating, overcurrent or fault voltage signal is received from the inverter, it is shut down. Converter When a malfunction is in the Hybrid vehicle control system, the HV ECU sends a signal to the converter, and the converter is stopped. MG1, MG2 Detects the position of the rotor of the MG1, 2 and controls the current flowing to the MG1, 2. In addition, the temperature is detected and the maximum load is controlled. Battery ECU Receives the SOC of the HV battery and the current value. Airbag Sensor Assembly Receives the airbag deployment signal. A/C ECU Receives the engine power rise demand (when air-conditioning is turned ON) and the engine running demand for water-temperature maintenance. Accelerator Pedal Position Sensor Receives the value corresponding to degree at which the accelerator pedal is depressed. Shift Position Sensor Receives the shift position signal (P, R, N, D, B). Cruise Control Switch Receives the cruise control switch signal. Stop Light Switch Receives the brake signal. Interlock Switch (for Inverter Cover and Service Plug) Verifies that the cover of both the inverter and the service plug have been installed. Circuit Breaker Sensor The high-voltage circuit is intercepted if a vehicle collision has been detected. Diagnosis When the HV ECU detects a malfunction, the HV ECU diagnosis and memorizes the values corresponding to the failure. Fail-Safe When the HV ECU detects a malfunction, the HV ECU stops or controls the actuators and ECUs according to the data already stored in memory. 28 THS (TOYOTA HYBRID SYSTEM) 2. Construction The configuration of the THS control system in the Prius is shown in the following chart. SENSORS ACTUATORS G-REF, SIN, COS HTE, ETH GO SPDO ESTP ECM MG1 G-MOTT HTD, DTH BATTERY ECU IB M-REF, SIN, COS HTB, BTH ABS ECU MG2 M-MOTT G-IU, IV, IW G-INVT INVERTER (for MG1) G-SINV, FINV SPD M-IU, IV, IW
Vehicle Speed Signal M-INVT INVERTER (for MG2) COMBINATION METER M-SINV, FINV VEHICLE SPEED SIGNAL (for Hybrid Transaxle) G-UU, VU, WU G-SDOWN ACCELERATOR PEDAL POSITION SENSOR VPA1, 2 SHIFT POSITION SENSOR SFT, P, R, N, D, B CRUISE CONTROL SWITCH CCS AIRBAG SENSOR ASSEMBLY ABFCS CIRCUIT BREAKER SENSOR ACS INTERLOCK SWITCH (for Inverter Cover and Service Plug) ILK HV ECU M-UU, VU, WU M-SDOWN NODD CONT 1 CONT 2 CONT 3 A/ C ECU ACON EGON STOP LIGHT SWITCH STP MREL IGCT RELAY SIL, TC BATT AUXILIARY BATTERY INVERTER (for MG1) MG1 INVERTER (for MG2) MG2 CONVERTER SYSTEM MAIN RELAY NO.1 SYSTEM MAIN RELAY NO.2 SYSTEM MAIN RELAY NO.3 DATA LINK CONNECTOR 3 29 THS (TOYOTA HYBRID SYSTEM) 3. ECM Control The ECM receives the demand torque and the target rpm which were sent from HV ECU (THE, ETH), and controls the degree of throttle valve opening, fuel injection timing, ignition time and VVT-i. In addition, the actual rpm is sent to the HV ECU with GO, and the speed signal from the hybrid transaxle is received through HV ECU with SPDO. When the vehicle is stopped, the HV ECU may send an engine stop (ESTP) command to the ECM to reduce fuel used. When a malfunction occurs in the system, the ECM activates MIL via the directions from the HV ECU. EF1 HTE, ETH ESA GO HV ECU VVT-i ECM SPDO Engine W M ESTP Throttle Control Motor 4. BRAKE ECU Control The brake ECU calculates the total braking force needed, based on the master cylinder pressure in the brake actuator generated when the driver depresses the brake pedal, and sends this valve to the HV ECU. The HV ECU computes a part for the regeneration brake force from the total braking force, and sends the result to the brake ECU. The HV ECU executes to the minus torque to MG2, and carries out the regenerative brake functions. The brake ECU controls the brake actuator solenoid valves and generates the wheel cylinder pressure, which is the regenerative brake force subtracted from the total braking force. Brake Actuator (Brake Master Cylinder) Pressure Signal Brake Actuator (Solenoid Valves) BRAKE ECU Pressure Sensors BTH Total Brake Force Requested HTB Regenerative Brake Force Transmitted HV ECU 30 THS (TOYOTA HYBRID SYSTEM) 5. Inverter Control (for MG1, MG2) The HV ECU transmits a signal to the power transistor in the inverter (G-UU, VU, WU, M-UU, VU, WU) for switching the U, V, W phase of the stator coil of MG1 and MG2, based on the rotor position information sent from MG1, 2 (G-SIN, COS, M-SIN, COS) and the SOC of the HV battery sent from the battery ECU. When shutting down the current to MG1, 2, a signal is sent to the inverter from the HV ECU (G-SDOWN, M-SDOWN). G-REF G-SIN, COS G-UU, VU, WU G-SDOWN Inverter (for MG1) Switching Signal Inverter (for MG2) Switching Signal MG1 HV ECU M-UU, VU, WU M-SDOWN MG2 M-SIN, COS M-REF Clutchless System A clutchless system has been adopted to keep the front wheels and MG2 linked mechanically via gears and a chain. To disengage the drive force in the neutral position, the N position signal from the shift position sensor turns OFF all the power transistors in the inverter (which connects the MG1 and the MG2) in order to shut down the operation of the MG1 and the MG2, thus rendering the drive force at the wheels to zero. In this state, even if the engine is running, the MG1 merely freewheels in the no-load state. Therefore, if the vehicle is allowed to operate continuously in the N position in a stationary state such as in heavy traffic, the SOC (state of charge) of the HV battery will continue to drop lower and lower. 6. Battery ECU The SOC, temperature and the voltage of HV battery are detected by the battery ECU, and this information is sent to HV ECU. 31 THS (TOYOTA HYBRID SYSTEM) – REFERENCE – The MG1 and the MG2 are generally shut down when the shift lever is in the N position. However, the shut-down function is canceled under the following exceptions:
During driving, if the brake pedal is depressed and a wheel locks up, the ABS is activated. After this, low torque is requested from the MG2 to provide supplemental power in order to restart the rotation of the wheel. Even if the shift lever is in the N position at this time, the shut-down function is canceled to allow the wheel to rotate. After the wheel rotation has been restarted, the system resumes its shut-down function.
When the vehicle is driven in the D or B position and the brake pedal is depressed, the regenerative brake operates. At this time, as the driver moves the shift lever to the N position, the brake hydraulic pressure increases while the request torque of the regenerative brake decreases gradually so as not to create a sluggish brake feel. After this, the system effects its shut-down function. When any of the conditions described below is present, the message prompt as shown appears in the multi information display, accompanied by the illumination of the master warning light and the continuous sounding of the buzzer.
The “READY” light is illuminated, the shift lever is in the N position, and the HV battery is discharged.
The “READY” light is illuminated, the shift lever is in the N position, and the driver’s door is open. 182TH33
The “READY” light is illuminated, the parking brake is engaged, the shift lever is in the B or D position, and the driver’s door is open. 32 THS (TOYOTA HYBRID SYSTEM) INDICATOR AND WARNING LIGHT The warning lights of the Prius are different from those on conventional vehicles. Inspection and repair should be performed while referring to the troubleshooting section in the 2001 Prius repair manual (RM778U).
Center Meter 
1. READY Light 2. Output Control Warning Light 3. Master Warning Light Multi Information Display  7. HV Battery Warning Light 5. Discharge Warning Light 4. Malfunction Indicator light 6. EMPS Malfunction Warning Light 8. Hybrid System Malfunction Warning Light 182TH22 1. READY light Turns on when the ignition switch is turned to START to indicate that the vehicle is ready to drive. 2. Output control warning light Turns on when the remaining HV battery charge becomes insufficient at R range or when there is an abnormal temperature rise in the HV battery due to continuous driving under heavy loads. It may also light when the HV battery temperature is low (after starting at low temperatures). The hybrid system output is limited while this light is on.  Travel at reduced speeds (avoid sudden acceleration) while the light is lit. 3. Master warning light Turns on with buzzer sounding by linked operation with warning lights “6” to “8” on the multi center display. 4. Malfunction indicator light Turns on when there is a malfunction in the engine control system. 5. Discharge warning light Turns on when there is a malfunction in the 12 V charging system (converter assembly).  If it turns on together with the master warning light and hybrid system warning light, check the diagnostic code. 6. EMPS malfunction warning light Turns on when there is a malfunction in the EMPS control system. 7. HV battery warning light Turns on when the HV battery is discharged to the lower limit. 8. Hybrid system warning light Turns on when a malfunction in MG1, 2, inverter, HV battery or HV ECU is detected. 33 THS (TOYOTA HYBRID SYSTEM) MG1 AND MG2 (MOTOR GENERATOR NO.1 AND NO.2) DESCRIPTION  Both the MG1 and the MG2 are compact, lightweight, and highly efficient alternating current permanent magnet synchronous type.  Serving as the source of supplemental motive force that provides power assistance to the engine as needed, the electric motor helps the vehicle achieve excellent dynamic performance, including smooth start-offs and acceleration. When the regenerative brake is activated, MG2 converts the vehicle’s kinetic energy into electrical energy, which is then stored in the HV battery.  MG1 recharges the HV battery and supplies electrical power to drive MG2. In addition, by regulating the amount of electrical power generated (thus varying the generator’s rpm), MG1 effectively controls the continuously variable transmission function of the transaxle. MG1 also serves as the starter to start the engine. Stator Stator Rotor Rotor Speed Sensor (Resolver) Speed Sensor (Resolver) MG1 MG2 Specifications  Permanent Magnet Motor (1CM) 273.6 33/(1040
5600) 350/(0
400) 351 Water-cooled Type Rated voltage [V] Maximum output [kW] (rpm) Maximum torque [N.m (kgf.m) (rpm) Amperage at maximum torque [A] Cooling system Performance Curve  N.m 350 300 Torque kW 40 Output 250 Torque
182CH04 200 30 150 20 Output
MG2 182CH05 100 10 50 0 0 1000 2000 3000 4000 5000 6000 0 Engine Speed (rpm) 182TH07 34 THS (TOYOTA HYBRID SYSTEM) 1. Permanent Magnet Motor When a three-phase alternating current is passed through the three-phase windings of the stator coil, a rotational magnetic field is created in the electric motor. By controlling this rotating magnetic field according to the rotor’s rotational position and speed, the permanent magnets that are provided in the rotor become attracted by the rotating magnetic field, thus generating torque. The generated torque is for all practical purposes proportionate to the amount of current, and the rotational speed is controlled by the frequency of the alternating current. Furthermore, a high level of torque, all the way to high speeds, can be generated efficiently by properly controlling the rotating magnetic field and the angles of the rotor magnets. U Phase Rotational Magnetic Field Stator Coil Rotor Attruction Repulsion V Phase W Phase : From inverter : Connected internally in the motor 182TH29 2. Speed Sensor (Resolver) This is an extremely reliable and compact sensor that precisely detects the magnetic pole position, which is indispensable for ensuring the efficient control of MG1 and MG2. The sensor’s stator contains 3 coils as illustrated, and output coils B and C are electrically staggered 90 degrees. Because the rotor is oval, the distance of the gap between the stator and the rotor varies with the rotation of the rotor. Thus, by passing an alternating current through coil A, output that corresponds to the sensor rotor’s position is generated by coils B and C. The absolute position can then be detected from the difference between these outputs. In addition, the amount of positional variance within a predetermined time is calculated by the HV ECU, thus enabling this sensor to be used as an rpm sensor. Magnetized Side Coil A Coil B Output Side Speed Sensor (Resolver) Coil C 182TH09 3. Power Cable Inverter The power cable is a high-voltage, high-amperage cable that connects the HV battery with the inverter, and the inverter with MG1 and MG2. Starting from the connector at the left front of the HV battery located in the luggage compartment, the power cable is routed under the rear seat, through the floor panel, along the under-the-floor reinforcement, and connects to the inverter in the engine compartment. A shielded cable is used for the power cable in order to reduce electromagnetic interference. The 12 V  wiring of the auxiliary battery also follows the same route. For identification purposes, the high-voltage wiring harness and connectors are color-coded orange to distinguish them from those of the ordinary low-voltage wiring. Junction Block Underthe-Floor Reinforcement Power Cable HV Battery Portion routed through the center floor Auxiliary Battery Power Cable 12 V Voltage  Power Cable Voltage
182TH10 35 THS (TOYOTA HYBRID SYSTEM) INVERTER 1. General The inverter is an electric power converter that converts the direct current of the Hybrid vehicle’s high-voltage battery (DC 273.6 V) and the alternating current of the MG1 and MG2. Consisting of 2 three-phase bridge circuits for MG1 and MG2, respectively, and each containing 6 power transistors, the inverter converts direct current and three-phase alternating current. The activation of the power transistors is controlled by the HV ECU. In addition, the inverter transmits information that is needed for current control, such as the output amperage or voltage, to the HV ECU. Together with MG1 and MG2, the inverter is cooled by the dedicated radiator of the coolant system that is separate from that of the engine. Inverter Converter 182TH26 2. System Diagram Inverter Bridge Circuit for MG2 Amperage Sensor HV Battery Ignition Signal Ground MG2 Voltage Detection Circuit Voltage Detection Circuit Signal Processor / Protective Function Processor HV ECU MG1 Amperage Sensor Bridge Circuit for MG1 3. Cooling System 182TH15 Reservoir Tank A cooling system via water pump for the inverter and MG1, 2 has been added. The HV ECU controls the water pump with coolant temperature. It is separated with the engine cooling system. Radiator Water Pump 182TH27 36 THS (TOYOTA HYBRID SYSTEM) CONVERTER 1. General Inverter The power source for auxiliary equipment of the vehicle such as the lights, audio system, and the air conditioner cooling fan, as well as the ECUs, is based on a 12 V system. Because the THS generator outputs at 273.6 V, the converter is used to transform the voltage from DC273.6 V to DC 12 V in order to recharge the auxiliary battery. The converter is installed on the underside of the inverter. Converter 182TH26 DC273.6 V Inverter 12 V
Output Input Filter F.L MAIN DC/DC Converter F.L DCDC Auxiliary Battery S34B20 Shielded 12 V S 20 V IG Converter Control Circuit NODD HV ECU A/C ECU IDH 182TH17 2. Operation
The DC273.6 V input is initially converted into alternating current by the transistor bridge circuit and transformed into a low voltage by the transformer. After this, the current is rectified, smoothed (into direct current) and converted into DC12 V.
The voltage at the positive terminal of the auxiliary battery is monitored by the converter and is maintained at a constant level. Consequently, the voltage of the auxiliary battery is unrelated to the engine rpm (even if the engine is stopped) and to the auxiliary equipment (output current of converter). 37 THS (TOYOTA HYBRID SYSTEM) HV BATTERY DESCRIPTION The sealed nickel metal hydride (Ni-MH) battery technology has been further evolved in the newly developed HV battery that offers features such as high power density, lightweight, and longevity, that are specifically designed to match the characteristics of the THS. Because the THS effects charge/discharge control to maintain a constant level of SOC (state of charge) while the vehicle is operating normally, it does not rely on the use of external rechargers. In the battery area, six 1.2-volt cells are connected in series to form one module. A total of 38 modules are divided into two holders and connected in series. Thus, the HV battery containing a total of 228 cells has a rated voltage of 273.6 V. The electrode plates in the HV battery are made of materials such as porous nickel and metal hydride alloy. Battery Pack Upper Case Service Plug Battery ECU SMR (System Main Relay) HV Battery Module 182TH34 38 THS (TOYOTA HYBRID SYSTEM) HV BATTERY CONTROL SYSTEM DESCRIPTION To maintain the battery at a proper SOC (state of charge), and to ensure safety in the event that the HV battery malfunctions, the battery ECU features the following control functions:
System Diagram  Battery Voltage for Each Module A/C ECU HV Battery Cooling Fan HV Battery Temp. Sensor Temp. Sensor (Circumference) Data Link Connector 3 Battery ECU Amperage sensor HV ECU A/C Signal     Amperage Signal Total Voltage Signal Charge or Discharge Signal Diagnosis CONSTRUCTION  The HV battery, battery ECU, and SMR (system main relay), are enclosed in a single case and placed in the luggage compartment behind the rear seat to make more effective use of vehicle space.  In the battery area, six 1.2-volt cells are connected in series to form one module. A total of 38 modules are connected in series. Thus, the HV battery containing a total of 228 cells has a rated voltage of 273.6 V.  A service plug that shuts off the circuit is provided in the middle of the 38 modules. Before servicing any portion of the high-voltage circuit, make sure to remove the service plug. For further details, refer to the 2001 Prius Repair Manual (Pub No. RM778U). HV Battery SMR2 SMR1 Battery Module (7.2 V x 19) Resistor Service Plug High-Voltage Fuse Battery Module (7.2 V x 19) SMR3 182TH11 39 THS (TOYOTA HYBRID SYSTEM) 1. Battery ECU The battery ECU provides the following functions. SOC (state of charge) Control While the vehicle is in motion, the HV battery undergoes repetitive charging/discharging cycles, as it becomes discharged by the MG2 during acceleration and charged by the regenerative brake during deceleration. The battery ECU outputs charge/discharge requests to the HV ECU so that the SOC can be constantly maintained at a center level, by estimating the charging/discharging amperage. Example of change in SOC Overcharged region Upper SOC control limit Control region SOC Target SOC control Lower SOC control limit Overcharged region Time 182TH12 Cooling Fan Control To ensure the HV battery’s performance considering the heat that is generated in the HV battery during charging and discharging, the battery ECU controls the operation of the cooling fan. HV Battery Malfunction Monitoring This function includes the monitoring of the temperature and the voltage of the battery via the battery ECU. If a malfunction is detected, the battery ECU protects the HV battery by restricting or stopping the charging and discharging of the HV battery. In addition, this function illuminates the warning light, outputs DTCs (Diagnostic Trouble Codes), and stores them in memory. For further details on the DTCs, refer to the 2001 Prius Repair Manual (Pub No. RM778U). 40 THS (TOYOTA HYBRID SYSTEM) 2. SMR (System Main Relay) The SMR is a relay that connects and disconnects the power source of the high-voltage circuit upon receiving a command from the HV ECU. A total of 3 relays, one for the negative side, and two for the positive side, are provided to ensure proper operations. At the time of connection, SMR1 and SMR3 are turned ON; after this, SMR2 is turned ON and SMR1 is turned OFF. By allowing the controlled current via the resistor to pass through initially in this manner, the circuit is protected against rush current. At the time of disconnection, SMR2 and SMR3 are turned OFF in that order, and the HV ECU verifies that the respective relays have been properly turned OFF. HV Battery SMR 2 SMR 1 Battery Module (7.2 V x 19) Resistor Service Plug High-Voltage Fuse Battery Module (7.2 V x 19) SMR 3 182TH11 3. Service Plug By removing the service plug before performing any inspection or service, the high-voltage circuit is shut off at the intermediate position of the HV battery, thus ensuring safety during service. The service plug assembly contains a reed switch for interlock. Lifting the clip lock up turns OFF the reed switch, which shuts off the SMR. However, to ensure safety, make sure to turn OFF the ignition switch before removing the service plug. For further details on how to handle the service plug, refer to the 2001 Prius Repair Manual (Pub No. RM778U). The main fuse for the high-voltage circuit is provided inside of the service plug assembly. Service Plug 182TH30 41 THS (TOYOTA HYBRID SYSTEM) HV BATTERY COOLING SYSTEM DESCRIPTION When the temperature of the HV battery rises, the battery ECU executes a command to cause the cooling fan to operate from OFF to LO, MID and HI speeds. However, if the air conditioning is being used at that time to cool the vehicle’s interior, and if there is still some margin left in the temperature of the HV battery, the battery ECU keeps the fan OFF or running at LO speed, thus giving priority to the air conditioning. The air intake for the cooling fan is located above the package tray trim. If an object (such as clothing) is placed over this area, the HV battery might not be able to cool sufficiently, which could cause the output control warning light to illuminate. Exhaust Duct No.1 Air Intake Cooling Fan Exhaust Duct No.2 HV Battery 182TH20 CONSTRUCTION This system feature a cooling fan which is driven by DC motor.
Specifications  Type Fan Size Dia x H Sirocco Fan mm (in.) 100 x 40 (4.0 x 1.6) Motor Type Air Flow Volume Power Consumption DC Motor Lo 50 m3 /h Mid Hi 100 W 150 60  The operation of the cooling fans is controlled by the signals that are output by the battery ECU, which monitors the temperature of the HV battery. 42 THS (TOYOTA HYBRID SYSTEM) AUXILIARY BATTERY DESCRIPTION The shielded, maintenance-free 12V battery (S34B20L) for the Prius is used. Battery fluid is filtered into separators in order to reduce hydrogen gas released which occurs when the battery is charged. Therefore, battery fluid does not need to be replaced, as long as the specified battery is used. Lead-calcium Alloy 182TH21 HV IMMOBILISER SYSTEM The HV immobiliser system has been designed to prevent the vehicle from being stolen. This system uses a ECM that stores the ID code of the authorized ignition key. If an attempt is made to start the HV system using an unauthorized key, the ECM prohibit fuel delivery and ignition, effectively disabling the engine. 79 CHASSIS – P111 HYBRID TRANSAXLE CHASSIS P111 HYBRID TRANSAXLE DESCRIPTION The P111 hybrid transaxle has been newly developed for the hybrid system application. Containing a MG (Motor Generator) 2 for driving the vehicle and a MG (Motor Generator) 1 for generating electrical power, the P111 hybrid transaxle uses a continuously variable transmission mechanism with power splitting device that achieve smooth and quiet operation. Power Splitting Device MG (Motor Generator) 2 MG (Motor Generator) 1 Oil Pump Transaxle Damper Differential 182CH01
Specifications  Planetary Pl t Gear The No. of Ring Gear Teeth 78 The No. of Pinion Gear Teeth 23 The No. of Sun Gear Teeth 30 Gear Ratio Chain Counter Gear Final Gear Fluid Capacity Fluid Type 3.905 Number of Links 74 Drive Sprocket 39 Driven Sprocket 36 Drive Gear 30 Driven Gear 44 Drive Gear 26 Driven Gear 75 Liters (US qts, Imp.qts) 4.6 (4.9, 4.0) ATF Type T-IV or equivalent 80 CHASSIS – P111 HYBRID TRANSAXLE TRANSAXLE UNIT 1. General The transaxle unit consists primarily of a transaxle damper, MG (Motor Generator) 1, MG2, power splitting device and a reduction unit (containing a silent chain, counter gears, and final gears). Power Splitting Device MG2 Sun Gear Carrier MG1 Ring Gear Transaxle Damper Engine Oil Pump Silent Chain Counter Gears Final Gears 182CH02 2. Transaxle Damper
A coil-spring type damper with low-twist characteristics has been adopted as the mechanism to transmit the drive force from the engine.
A torque fluctuation absorbing mechanism that uses a dry-type single-plate friction material has been adopted. Coil Spring Drive force from the engine 182CH03 81 CHASSIS – P111 HYBRID TRANSAXLE 3. MG (Motor Generator) 1 The MG1 recharges the HV (Hybrid Vehicle) battery and supplies electrical power to drive the MG2. In addition, by regulating the amount of electrical power generated, thus varying the MG2’s speed, the MG1 effectively controls the continuously variable transmission function of the transaxle. Connected to the sun gear of the planetary gear unit, MG1 also functions as a starter for starting the engine. Stator Rotor 182CH05 4. MG (Motor Generator) 2 Serving as the source of supplemental motive force that provides power assist to the output of the engine as needed, the electric motor helps the vehicle achieve an excellent dynamic performance that includes smooth start-offs and acceleration. Connected to the ring gear in the planetary gear unit, MG2 is an electric motor that converts the vehicle’s kinetic energy that is generated through the activation of the regenerative brake into electrical energy, which is then stored in the HV batteries. Stator Rotor 182CH04 82 CHASSIS – P111 HYBRID TRANSAXLE 5. Power Splitting Device General Planetary gear unit is used for a power splitting device. As part of the planetary gear unit, the sun gear is connected to MG1, the ring gear is connected to MG2, and the carrier is connected to the engine output shaft. The motive force is transmitted via the chain to the counter drive gear. Connection Item Ring Gear Planetary Gear Unit Carrier Sun Gear MG1 MG2 Transaxle Damper Oil Pump Sun Gear MG1 Ring Gear MG2 Carrier Engine Output Shaft MG2 Engine Chain MG1 Counter Gear Final Gear 182CH06 Engine Output Shaft 182CH77 Operation 1) Starting the Engine Both while the vehicle is stopped and is in motion, the starting of the engine is performed by MG1. Because the motive force is transmitted at this time to the ring gear in the planetary gear unit, an electrical current is applied to MG2 to cancel out the motive force (reactive control). The nomographic chart below gives a visual representation of the planetary gear’s rotational direction, rotational speed, and power balance. In the nomographic chart, the rpm of the 3 gears maintain a relationship in which they are invariably joined by a direct line. : Flow of : Torque HV Battery : motive force : MG2 : Flow of Inverter : Torque Discharge : electrical force MG2 MG1 Reactive Control Sun Gear Carrier Ring Gear rpm Engine MG1 Engine MG2 182CH08 Nomographic Chart of Planetary Gear Unit 182CH07 83 CHASSIS – P111 HYBRID TRANSAXLE 2) Generation During Shift Position P When the shift lever is in the P position, if the SOC (State Of Charge) of the HV batteries exceeds the specified value, the engine remains stopped. However, if the SOC is below the specified value, the engine operates to generate electricity through MG1 in order to recharge the HV batteries. At this time, reactive control is effected to allow the electric current to flow from the HV batteries to MG2, thus receiving the reactive force of MG2. : Flow of HV Battery : motive force : Torque : Flow of Inverter : electrical force : MG2 Discharge Recharging : Torque MG1 Generate Reactive MG2 Sun Gear Carrier Ring Gear Control rpm Engine MG1 Engine MG2 182CH10 Nomographic Chart of Planetary Gear Unit 182CH09 3) Starting and Light-Load Driving When the vehicle is started off or is being driven under light-load conditions, and the SOC of the HV batteries exceeds the specified value, the vehicle operates powered only by MG2. At this time, the engine remains stopped, and MG1 is spinning in the opposite direction without generating electricity. If the SOC is below the specified value, the engine operates to generate electricity through MG1 in order to recharge the HV batteries. : Driving : Flow of HV Battery : Load : motive force : MG2 : Flow of Discharge Inverter : Torque : electrical force MG2 MG1 Drive Sun Gear Carrier Ring Gear rpm Engine MG1 Engine MG2 182CH12 Nomographic Chart of Planetary Gear Unit 182CH11 84 CHASSIS – P111 HYBRID TRANSAXLE 4) Normal Traveling When the vehicle is being driven under normal traveling condition, the motive force of the engine is divided by the planetary gears. A portion of this motive force is output directly, and the remaining motive force is used for generating electricity through MG1. Through the use of an electrical path of an inverter, this electrical force is sent to MG2 to be output as the motive force of MG2. Under further high-load conditions, the electrical force from the HV batteries is also used as a motive force of MG2. HV Battery Discharge Inverter Recharging Electrical Path MG2 : Flow of : motive force : Flow of : electrical force : Torque : Driving Load : MG2 Torque MG1 Generation Drive Sun Gear Carrier Ring Gear rpm Engine MG1 Engine MG2 182CH14 Nomographic Chart of Planetary Gear Unit 182CH13 5) Deceleration Driving If the SOC of the HV batteries is within the specified value during deceleration, electricity is generated by MG2 to recharge the HV batteries. If the SOC is excessive, the apportionment of energy to the hydraulic brakes is increased. However, if the shift lever is in position B, the engine is started by MG1 in order to apply the engine brake. HV Battery Inverter Recharging Electrical Path MG2 MG1 Speed Control : Flow of : motive force : Flow of : electrical force : Driving : Load : MG2 : Torque Generation Sun Gear Carrier Ring Gear Speed Control rpm Engine MG1 Engine MG2 182CH18 Nomographic Chart of Planetary Gear Unit 182CH17 85 CHASSIS – P111 HYBRID TRANSAXLE 6) Reverse Driving The vehicle drives in reverse powered only by MG2. If the SOC of the HV batteries exceeds the specified value, the vehicle drives powered only by MG2. If the SOC is below the specified value, the engine starts, and the electrical force generated by MG1 passes through the electrical path function of the inverter in order to be used as the motive force of MG2. HV Battery Inverter Discharge Electrical Path MG2 Drive : Flow of : motive force : Flow of Recharging : electrical force MG1 : Driving Load : MG2 Torque Generation Sun Gear Corrier Ring Gear rpm Engine MG1 Engine MG2 182CH20 Nomographic Chart of Planetary Gear Unit 182CH19 NOTICE Because it is not possible for this transaxle to separate the MG2 output force from the drive wheels when the shift lever is in position N, the generation of electricity is disabled. In this condition, the generation of electricity could cause the motive force to be transmitted, which creates a hazardous situation. Therefore, beware that the HV batteries could become discharged in this state. 86 CHASSIS – P111 HYBRID TRANSAXLE 6. Reduction Unit The reduction unit consists of the silent chain, counter gears and final gears. A silent chain with a small pitch width has been adopted to ensure quiet operation, and the overall length has been reduced in contrast to the gear-driven mechanism. The counter gears and final gears teeth have been processed through high-precision housing and their tooth flanks have been optimized to ensure extremely quiet operation. The final gears have been optimally allocated to reduce the distance between the engine’s center shaft and the differential shaft, thus resulting in a transmission with a compact package. Silent Chain Engine’s Center Shaft Counter Gears Final Gears Differential Shaft 182CH21
DIFFERENTIAL UNIT For the differential unit, a 2-pinion type that is similar to the differential unit of the conventional transaxle has been adopted. 87 CHASSIS – P111 HYBRID TRANSAXLE
LUBRICATION SYSTEM A force-feed lubrication system using a trocoid pump has been adopted for lubrication of the planetary gear unit and the bearings on the main shaft. The oil pump is directly driven by the engine. The same type of oil is used for both the reduction unit portion and the differential portion. Oil Pump Drive Shaft Oil Pump Drive Rotor Oil Pump Driven Rotor 182CH22
PARKING LOCK MECHANISM A mechanical parking lock mechanism has been provided in the counter driven gear. The engagement of the parking lock pawl with the parking gear that is integrated with the counter driven gear locks the movement of the vehicle. The direction of the parking lock pawl changes via the two link mechanisms that are connected to the outer lever through the shift cable. The longitudinal movement of the parking rod causes a vertical movement of the parking lock pawl that meshes with the parking gear. Parking Gear Parking Lock Pawl 182CH23 Link 2 Link 1 Parking Rod “A” View Link 2 “A” View Parking Lock Pawl 182CH24 88 CHASSIS – P111 HYBRID TRANSAXLE
SHIFT CONTROL 1. Shift Lever A column-type shift lever with 5 positions has been adopted. The shift lever is operated by moving it in the vehicle’s longitudinal direction to ensure excellent ease of use. The shift lever is integrated with the shift position sensor. 2. Shift Control For shift control, a shift-by-wire system has been adopted. This system uses electrical signals that are output by the shift position sensor to determine the shift position. For operating the parking lock pawl in the transaxle, however, a shift cable is used for attaining P position. The shift position sensor outputs two systems of signals: the main switch signals, and the sub switch signals containing high and low voltages. When these signals match, the HV ECU determines the respective shift position. Shift Position Sensor 182CH25 Voltage Main Shift Position Sensor HV ECU Engine ECU Sub Serial Data Link Combination Meter : Defined : Region Voltage Signal B D N R P Stroke P R N D B Switch Signal 182CH26 Service Tip Because it is extremely difficult to precisely assemble the shift position sensors, do not disassemble the shift lever. 89 CHASSIS – P111 HYBRID TRANSAXLE
SHIFT LOCK SYSTEM 1. General A shift lock system that help prevent the unintended operation of the shift lever has been provided. The shift lock system consists of a key interlock device and shift lock mechanism. 2. Layout of Components Shift Control Switch Key Interlock Solenoid Shift Lock Solenoid Shift Lock ECU Shift Lock Override Lever 182CH78 3. Function of Components Components Function P Position Detection Switch Detects whether or not the shift lever is in P position and sends signals to the shift lock ECU. Key Interlock Solenoid Regulates the movement of the ignition key cylinder. Shift Lock Solenoid Regulates the operation of the shift lever at P position. Stop Light Switch Sends the brake signal to the shift lock ECU. Shift Lock ECU Receives inputs of various types of signals and regulates the operation of the two solenoids. 90 CHASSIS – P111 HYBRID TRANSAXLE 4. Key Interlock Device The activation of the key interlock solenoid that is mounted on the upper column bracket moves the lock pin to restrict the movement of the key cylinder. Therefore, if the shift lever is shifted to any position other than “P”, the ignition key cannot be moved from “ACC” to the “LOCK” position. 5. Shift Lock Mechanism The shift lock mechanism prevents the shift lever from being shifted out of the “P” position to any other position unless the ignition switch is turned ON and the brake pedal is pressed. A shift lock override lever, which manually overrides the shift lock mechanism, is provided. 91 CHASSIS – DRIVE SHAFT DRIVE SHAFT DESCRIPTION
A tripod type CVJ (Constant Velocity Joint) is used on the differential side, and Rzeppa type CVJ is used on the front axle side.
A dynamic damper has been provided on the right driveshaft to reduce vibration and noise. Tripod Type CVJ Rzeppa Type CVJ Front Axle Side Differential Side Left Side 182CH27 Rzeppa Type CVJ Tripod Type CVJ Dynamic Damper Front Axle Side Differential Side Right Side 182CH28 92 CHASSIS – SUSPENSION AND AXLES SUSPENSION AND AXLES SUSPENSION 1. General  MacPherson strut type suspension that uses L-shaped lower arms has been adopted for the front.  Torsion-beam type suspension with toe control links has been adopted for the rear.  The characteristics and the allocation of the components have been optimized to ensure excellent drivability, stability, and riding comfort. 182CH29
Specifications  Item Front Rear mm (in.) 1480 (58.3) 1478 (58.2) Caster* degrees 102’ — Camber* degrees –026’ –130’ Toe-In* mm (in.) 1 (0.04) 1 (0.04) degrees 952’ — Tread King Pin Inclination* *: Unloaded Vehicle Condition 93 CHASSIS – SUSPENSION AND AXLES 2. Front Suspension General A MacPherson strut type independent suspension with an L-shaped lower arm has been adopted. Through the optimal allocation of components, and the adoption of the nachlauf geometry, negative camber, and antidive geometry, the front suspension realizes excellent riding comfort, stability, and controllability. 182CH30 Nachlauf Geometry The front suspension adopts the nachlauf geometry in which the king pin axis is located ahead of the axle center. As a result, excellent straightline stability has been realized and the steering feeling has been improved. King Pin Axis Axle Center Front 181CH22 94 CHASSIS – SUSPENSION AND AXLES Negative Camber The front suspension adopts negative camber to reduce the ground contact camber angle of the outer wheel at the time of turning (cornering), which is caused when the vehicle posture changes during cornering, thus realizing excellent cornering performance. Negative Camber Straightline Cornering 181CH23 181CH24 Suspension Upper Support and Dust Cover  The upper support optimizes the characteristics of the rubber mount. Also, a rebound stopper has been provided to ensure riding comfort, drivability, and stability. Bound Stopper  A bound stopper made of urethane has been adopted. By optimizing the stopper characteristics and the clearance, excellent riding comfort and a high level of roll rigidity have been achieved.  An upper insulator that is integrated with the dust boot has been adopted. Rebound Stopper Upper Insulator Stopper Clearance 182CH31 95 CHASSIS – SUSPENSION AND AXLES Shock Absorber  Low-pressure (N2) gas sealed shock absorbers that offer stable dampening force characteristics without causing cavitation have been adopted.  The dampening force characteristics of the shock absorbers have been optimized to achieve excellent riding comfort, drivability, and stability. Lower Arm  An L-shaped stamped lower arm has been adopted.  Rubber bushings have been adopted, and the mounting position and the construction of the lower arm have been optimized to improve the steering feel. Rear Bushing A Front Bushing A A – A Cross Section Front Bushing Cross Section Rear Bushing Cross Section 182CH32 Stabilizer Bar A ball-joint type stabilizer link has been adopted. Also, by mounting the stabilizer link to the shock absorber, the excellent stabilizing efficiency has been provided while realizing both steering stability and riding comfort. Ball Joint Stabilizer Link Stabilizer Bar Stabilizer Link 182CH33 96 CHASSIS – SUSPENSION AND AXLES 3. Rear Suspension General
A torsion beam type suspension with toe control links has been adopted, in which an axle beam is located in the middle of the trailing arm.
The torsion beam type rear suspension minimizing change in the tire-to-road camber during cornering, thus delivering good cornering stability and driving stability.
The stabilizer bar has been adopted to realize excellent drivability and stability.
A toe control link mechanism has been adopted in the construction of the trailing arm bushings. The toecorrect function that is effected by the movement of the links results in optimal compliance steering, thus achieving excellent drivability, stability, and riding comfort at high levels. NOTICE Be sure to use the jack-up points that are provided on the body when raising the vehicle on a jack. Never apply a jack under the axle beam, training arm, or the bushing of the rear suspension. Never use these areas as jack-up points. 182CH34 97 CHASSIS – SUSPENSION AND AXLES Trailing Arm and Axle Beam
Trailing arms that are lightweight, highly rigid, hollow inside, and a gently curved axle beam with a rearopen U-shaped cross section have been adopted.
A toe control links integrated axle beam has been adopted. The toe control link consists of the No.1, No.2, and No.3 trailing arm bushings, and it rotates within the horizontal plane of the vehicle, around the No.3 bushing that serves as the axial center.
The rolling regidity has been optimized through the adoption of the stabilizer bar. Toe-Control Link No.2 Trailing Arm Bushing No.1 Trailing Arm Bushing Trailing Arm Axle Beam Trailing Arm No.2 Trailing Arm Bushing No.3 Trailing Arm Bushing 182CH35 Toe-Correct Function The longitudinal and lateral forces that are created in the vehicle during cornering causes the toe control links in the trailing arms to become deformed. On a right turn, the right trailing arm moves forward and the left trailing arm moves rearward, creating a tendency for the left wheel to toe out. In this situation, the toe control links that are installed in the trailing arms are designed to utilize the lateral force, which is applied to the toe control links during cornering, to correct the left trailing arm towards the toe-in direction. As a result, excellent stability and controllability are realized. Lateral Force Lateral Force Applied to the Toe Control Link Lateral Force Lengthwise Force Bushing Movement Toe Control Links Left-Side Wheel Left-Side Wheel 181CH35 98 CHASSIS – SUSPENSION AND AXLES Toe and Camber Change In the torsion beam type suspension, the camber angle and the toe change differ between the same direction stroke case and the opposite direction stroke case, offering both straightline stability and excellent cornering stability. 1) Same Direction Stroke Case Similar to the full-trailing arm type suspension, the axis that joins the center of the right and left trailing arm bushings is the center of the movement. 2) Opposite Direction Stroke Case During opposite direction stroke case, or if a difference in suspension travel is created between the right and left wheels, the torsion beam twists with its shearing center as the center of its rotation. Also, camber changes in relation to the suspension travel are determined by the ratio of the distance between the No.1 trailing arm bushing and the axle center and the shearing center (‘α’ in the Fig. below) and distance between the No.1 trailing arm bushing and the axle beam (‘L’ in the Fig. below). Consequently, through the optimal allocation of the axle beam, the changes in the camber angle in relation to the suspension travel have been optimized, thus ensuring excellent cornering performance. Center of Bushing BOUND Instantaneous Center of Right Axle Center of Bushing Camber Change Rate α/L Camber Change Rate 100% An alignment change that is very close to that of the semi-trailing suspension is effected. REBOUND α L 165CH48 Shock Absorber
Low-pressure (N2) gas sealed shock absorbers that offer stable dampening force characteristics without causing cavitation have been adopted.
The dampening force characteristics of the shock absorbers have been optimized to achieve excellent riding comfort, drivability, and stability. 99 CHASSIS – SUSPENSION AND AXLES AXLES 1. Front Axle
The front axle use a double-row angular ball bearing which offers low rolling resistance.
A lock nut (12-point) has been adopted and staked for tightening the axle hub in order to ensure the tightening performance. This nut cannot be reused. 12-point Nut Double-Row Angular Ball Bearing 182CH36 2. Rear Axle
The rear axle use a double-row angular ball bearing which offers low rolling resistance. ABS Speed Sensor
ABS speed sensor and rotor are built in the axle bearing. Double-Row Angular Ball Bearing 182CH37 100 CHASSIS – BRAKES BRAKES DESCRIPTION  The front brakes use ventilated disc brakes and the rear brakes use leading-trailing drum brakes.  To adjust the clearance between the shoes and drum, the rear drum brakes uses the incremental type hydraulic auto adjuster.  On the Prius uses a pedal type parking brake that is released by pressing the pedal further.  A hydraulic brake booster in which the master cylinder and booster are integrated has been adopted.  The Prius has adopted the ABS with EBD (Electronic Brake force Distribution) as a standard equipment.  A regenerative brake system, which uses the MG2 that is used for driving the vehicle as a generator to efficiently convert the energy that is created during braking has been adopted. This system enables to collect more driving energy by having the control to cooperate the hydraulic brake and the regenerative brake. 182CH38 101 CHASSIS – BRAKES
Specifications  Master Cylinder Type Diameter Single mm (in.) Brake Booster Type Hydraulic Type Front Brake Ventilated Disc Caliper Type PE54 Wheel Cylinder Dia. mm (in.) 54.0 (2.13) Rotor Size (D x T)* mm (in.) 255 x 22 (10.04 x 0.87) Type Rear Brake Leading-Trailing Drum Wheel Cylinder Dia. mm (in.) 20.64 (0.81) Drum Inner Dia. mm (in.) 200 (7.87) Brake Control Valve Type P & B Valve Type Parking g Brake 22.22 (0.87) Size Lever Type ABS with EBD Drum mm (in.) 200 (7.87) Pedal STD *: D: Outer Diameter, T: Thickness FRONT BRAKE The PE54 type brake calipers and ventilated disc rotor have been adopted. These brake calipers are lightweight and compact to realize excellent brake performance. 182CH39 REAR BRAKE General  The leading-trailing type drum brakes using drums with a 200 mm (7.87 in.) inner diameter have been adopted.  A hydraulic system that adjusts the clearance between the shoes and the drum has been adopted. 182CH40 102 CHASSIS – BRAKES Incremental Type Hydraulic Auto Adjuster Ordinarily, when the rear brakes are applied, the shoes expand until they come in contact with the inner surface of the drum. While the auto adjust lever remains in contact with point A of the strut, the spring force causes the auto adjust lever to rotate in direction C, with adjust lever point B as the fulcrum. At this time, if the shoe clearance exceeds a predetermined amount, the tip of the auto adjust lever rotates the adjusting bolt in direction D by 1 tooth, causing the strut to move for a predetermined amount towards the direction that expands the shoes. As a result, by pushing and expanding the initial position of the shoes, an appropriate amount of clearance is maintained between the shoes and the drum. Wheel Cylinder Adjusting Bolt Shoe Strut A D Auto Adjust Lever C B Spring 165CH33 PARKING BRAKE 1. General On the Prius uses a pedal type parking brake that is released by pressing the pedal further. 2. Construction A pedal type parking brake pedal consists mainly of a parking brake pedal, sector, pawl, release intermediate lever, pawl spring and pedal return spring. The parking brake pedal and sector are integrated, and parking brake cable is attached to the parking brake pedal. The pawl and the release intermediate lever are linked by the pawl spring and operate together along with the movement of the pedal. Pawl Spring Release Intermediate Lever Pawl Sector Parking Brake Cable 182CH41 103 CHASSIS – BRAKES 3. Operation During Applying Pressing the parking brake pedal causes the sector’s rachet to engage with the pawl. Then, when the pressure on the brake pedal is released, the reaction force of the parking brake cable and the force of the pedal return spring cause the pawl and sector, which remain engaged, to return (only for the stroke). As the result, the parking brake becomes locked. At this time, because the relative installed position of the pawl spring changes, the force of the pawl spring that was applied to the intermediate release lever switches its direction and now pushes the intermediate release lever down. Stroke Reaction Force of Parking Brake Cable While Pressing Locked State 182CH42 During Releasing When the parking brake pedal is pressed again, as the reaction force of the parking brake cable and the force of the pedal return spring will not be applied to the pawl, the action of the pawl spring causes the pawl to lift. As a result, the pawl is released from the sector’s ratchet. Next, when the parking brake pedal returns to its initial point, the lift portion of the parking brake pedal causes the intermediate release lever to lift. The pawl is then pushed down by the force of the pawl spring and returns to its initial state. Lift Portion of Parking Brake Pedal Press Again During Pedal Return 182CH43 104 CHASSIS – BRAKES BRAKE SYSTEM 1. General
A brake system, which uses brake fluid that is stored under high pressure to assist the brake pedal effort and to operate the ABS with EBD control and the regenerative brake cooperative control, has been adopted.
A regenerative brake system, which uses the MG2 that is used for driving the vehicle as a generator to efficiently convert the energy that is created during braking, has been adopted. This system enables to collect more driving energy by having the control to cooperate the hydraulic brake and the regenerative brake. 2. System Diagram Rear Front Brake Actuator Stroke Simulator Hydraulic Brake Switching Valve Hydraulic Brake Hydraulic Adjustment Area Regenerative Brake ABS Function Area Differential Gear MG2 Power Splitting Device Engine MG1 Inverter HV Battery THS (TOYOTA Hybrid System) 182CH44 3. Layout of Main Components Reservoir Tank Solenoid Relay ECM Pump Motor Relays Combination Meter Brake ECU Brake Warning Buzzer Rear Wheel Speed Sensors and Rotors Hydraulic Brake Booster Power Supply portion Hydraulic Brake Booster (Master Cylinder Portion) HV ECU Brake Actuator Front Wheel Speed Sensor and Rotor 182CH45 105 CHASSIS – BRAKES 4. Function of Main Components Components ABS Warning Light Combination Meter Brake System Warning Light Stop Light Switch Function Lights up to alert the driver when the brake ECU detects the malfunction in the ABS.
Lights up together with the ABS warning light to alert the driver when the brake ECU detects the malfunction not only in the ABS but also in the EBD control control.
Lights up to alert the driver when the malfunction occurs in the brake system. Detects the brake depressing signal. Brake Warning Buzzer Emits a continuous sound to inform the driver that the ABS ECU detects the malfunction in the hydraulic brake booster. Speed Sensors Detect the wheel speed of each of the four wheels. Brake ECU
Processes various sensor signals, regenerative brake signals, to execute control of the ABS control, EBD control, regenerative coordination control and hydraulic brake booster.
Communicates control data with the HV ECU. HV ECU Maintains serial communication with the brake ECU to exchange regenerative coordination control signals. Hydraulic Brake Booster
Assists with the pedal effort applied to the brake pedal.
Supplies hydraulic pressure. Brake Actuator Controls the brake fluid pressure to each brake wheel cylinder by signals from the brake ECU. Solenoid Relay Supplies power to the ABS’s solenoid valve’s in the brake actuator. Pump Motor Relays Control the pump motor operation in the hydraulic brake booster. 106 CHASSIS – BRAKES 5. Hydraulic Circuit Accumulator Hydraulic Brake Booster Pump and Pump Motor Pressure Switch PH Pressure Switch PL Master Cylinder and Brake Booster Brake Actuator Pressure Sensor Pressure Sensor SLR SLA Stroke Simulator SS SMC1 SMC2 Pressure Sensor Reservoir Pressure Sensor SFLH SFRH SRrH SRrR SFRR SFLR P & B Valve Rear Wheel Cylinders SMC1 SMC2 SS Switching Solenoid Valves SLA SLR Linear Solenoid Valves Front Wheel Cylinders SFRH SFRR SFLH SFLR SRrH SRrR 182CH46 ABS Solenoid Valves 107 CHASSIS – BRAKES 6. Construction and Operation The brake system of Prius consists of the following components: Components Power Supply Portion Hydraulic Brake Booster Master Cylinder Portion Brake Actuator Function Pump and Pump Motor Draws up the brake fluid from the reservoir tank and provides high hydraulic pressure to the accumulator. Accumulator Stores the hydraulic pressure that was generated by the pump. The accumulator is filled with highpressure nitrogen gas. Pressure Switches Monitors the hydraulic pressure of the accumulator and outputs control signals for the pump motor. There are two types: the pressure switch PH for controlling the pump, and the pressure switch PL for giving a warning when the pressure is low. Relief Valve Returns the brake fluid to the reservoir tank to prevent excessive pressure if the pump operates continuously due to a malfunction of the pressure switch. Reservoir Tank Stores the brake fluid. Brake Fluid Level Warning Switch Detects the low brake fluid level. Master Cylinder Generates the hydraulic pressure in accordance with the pedal effort that is applied to the brake pedal. Brake Booster Regulates the accumulator pressure in accordance with the pedal effort that is applied to the brake pedal and introduces this pressure to the booster chamber in order to provide a power assist to the brakes. Pressure Sensors Detects the pressure of the master cylinder, regulator, and front and rear wheel cylinders. Switching Solenoid Valves Switches the hydraulic path between normal braking and braking under control. ABS Control Solenoid Valves Pressure Holding Valves Pressure Reduction Valves Controls the hydraulic pressure that is applied to the wheel cylinders during ABS control or EBD control. Linear Solenoid Valve Regulates the hydraulic pressure to the wheel cylinders during braking in accordance with the fluctuations in the regenerative brake force. Reservoir Temporarily stores the brake fluid when regulating the hydraulic pressure to the wheel cylinders in accordance with the fluctuations in the regenerative brake force. Stroke Simulator Generates a pedal stroke during braking in accordance with the driver’s pedal effort. 108 CHASSIS – BRAKES Hydraulic Brake Booster 1) General Due to installation space constraints, a type of hydraulic brake booster that comprises two separate portions has been adopted: the power supply portion (pump, pump motor, accumulator, pressure switches, and relief valve) and the master cylinder portion. Consisting of an pump and pump motor, accumulator, and hydraulic pressure switches, the hydraulic brake booster performs the functions of both the booster and the master cylinder. By optimizing the hydraulic circuits, the hydraulic pressure that is generated by the booster is applied directly to the rear brakes. Thus, the hydraulic pressure from the master cylinder is used exclusively by the front brakes. 2) Pump and Pump Motor, Accumulator, Pressure Switches and Relief Valve If the accumulator pressure becomes lower than the pressure that is specified in the pressure switch PH, which is used for detecting high pressure, the pressure switch PH turns OFF. Then, the brake ECU turns ON the pump motor relays to operate the pump motor and the pump. The brake fluid that is discharged by the pump passes through the check valve and is stored in the accumulator. The hydraulic pressure that is stored in the accumulator is used for providing the hydraulic pressure that is needed for normal braking, for operating the ABS, and for operating the EBD control, and for regenerative brake cooperative controlling. If the accumulator pressure becomes higher than the pressure that is specified in the pressure switch PH, the pressure switch PH turns ON. Then, after several seconds, the brake ECU turns OFF the pump. At this time, if the pressure switch PH malfunctions and causes the pump to operate continuously, the relief valve opens to prevent excessive pressure from being generated. Moreover, if the accumulator pressure becomes lower than the pressure that is specified in the pressure switch PL, which is used for detecting low pressure, the pressure switch PL turns OFF. As a result, the brake system warning light turns ON and the brake warning buzzer activates. At this time, the ABS or EBD is prohibited from operating. Accumulator Pressure Reservoir Tank Accumulator Pressure ON Switch PH OFF Relief To Master Valve Cylinder and Solenoid Valves Pressure Switch PL Brake ECU Brake Warning Buzzer OFF Pressure Switch PL Check Valve Pressure Switch PH Time Pump and Pump Motor Pump Motor ON Relief Valve Open OFF Pump Motor Relays Brake System Warning Light Close Brake System ON Warning Light and Brake Warning Buzzer OFF 182CH47 152CH17 109 CHASSIS – BRAKES 2) Master Cylinder and Brake Booster a. Construction  This construction enables the hydraulic pressure that is generated by the brake booster to be applied directly to the rear brakes.  The master cylinder is the center port type single master cylinder, which is used for the front brakes only.  The brake booster is integrated with the master cylinder. The operating portion, master cylinder, and regulator are positioned coaxially to achieve a simple and compact construction.  The operating rod and the power piston are linked directly to transmit the pedal effort that is applied to the brake pedal.  The regulator and the spool valve are linked directly. A forward (leftward) force generated by the master cylinder pressure and a rearward (rightward) force generated by the power assist of the booster are applied to the regulator. Both forces maintain a balance.  A return spring is provided for the regulator to ensure the return of the spool valve.
Cross-Sectional Drawing  Return Spring Spool Valve Master Cylinder Piston Regulator Power Piston Reaction Rod Operating Rod Rubber Reaction Disc Master Cylinder Regulator
Operating Portion 182CH48 Simplified Drawing  Reaction Rod Power Piston Regulator To From Reservoir Accumulator From Reservoir Tank Operating Rod Rubber Reaction Disc Rear Brake Front Brake Spool Valve Master Cylinder Piston 152CH24 110 CHASSIS – BRAKES b. Operation i) Pressure Increase (Low Pressure) The pedal effort that is applied to the brake pedal is transmitted via the operating rod, power piston, and master cylinder piston. However, because the load setting of the master cylinder’s return spring is higher than that of the regulator piston’s return spring, the regulator piston gets pushed before the volume in the master cylinder becomes compressed. As a result, the spool valve moves forward. The spool valve closes the port “A” between the reservoir and the booster chamber (behind the power piston) and opens the port “B” between the accumulator and the booster chamber. Then, the pressurized brake fluid is introduced into the booster chamber to provide a power assist to the pedal effort. When the pressure is introduced into the booster chamber, the power assist overcomes the force of the master cylinder’s return spring. This causes the volume in the master cylinder to become compressed and increases the pressure that is applied to the front brakes. At the same time, the pressure in the booster chamber increases the pressure that is applied to the rear brakes. During the initial stage of the brake operation, the booster pressure that is applied to the rubber reaction disc is small. Therefore, a return force in the rightward direction does not apply to the spool valve via the reaction rod. Power Piston Regulator Reaction Rod To From Reservoir Accumulator From Reservoir Tank Spool Valve Operating Rod Rubber Reaction Disc Return Spring “A” “B” Booster Chamber To Rear Brake To Front Brake Return Spring Master Cylinder Piston 152CH25 ii) Pressure Increase (High Pressure) In contrast to the time when the pressure is low, when the pressure is high, the booster pressure that is applied to the rubber reaction disc increases. Accordingly, the rubber reaction disc deforms and causes a return force in the rightward direction to be applied to the spool valve via the reaction rod. Therefore, in contrast to the time when the pressure is low, a greater reaction force is transmitted to the brake pedal. As a result, a variable servo mechanism is realized, in which the servo ratio is lower during high pressure than during low pressure. Power Piston Regulator Reaction Rod To From Reservoir Accumulator From Reservoir Tank Rubber Reaction Disc Booster Chamber To Rear Brake Spool Valve To Front Brake Master Cylinder Piston 152CH26 111 CHASSIS – BRAKES iii) Holding This is a state in which the force that is applied via the brake pedal and the master cylinder pressure are in balance. The forces that are applied to the front and the rear of the regulator piston, in other words, forces that are generated by the master cylinder pressure and the regulator pressure become balanced. This causes the spool valve to close both port “B” from the booster chamber to the accumulator and port “A” to the reservoir. As a result, the brake system is in the holding state. To From Reservoir Accumulator “A” “B” Regulator To Rear Brake From Reservoir Tank To Front Brake 182CH82 Spool Valve iv) Pressure Reduce When the force that is applied to the brake pedal is relaxed, the master cylinder pressure decreases. Then, the regulator’s return (rightward) force becomes relatively greater, causing the regulator to retract and the spool valve to also retract. As a result, the port “A” between the reservoir and the booster chamber opens. The booster pressure becomes reduced in this state, creating a balance that corresponds to the force that is newly applied via the brake pedal. This process is performed repetitively to reduce the booster pressure and the master cylinder pressure in accordance with the force that is applied via the brake pedal. To Reservoir “A” From Accumulator Regulator To Reservoir Tank Booster Chamber From Rear Brake From Front Brake Spool Valve 152CH28 112 CHASSIS – BRAKES v) During Power Supply Malfunction If the accumulator pressure is affected due to some type of malfunction, no pressure will be supplied by the regulator. Then, a power assist cannot be provided to the force that is applied via the brake pedal and the pressure to the rear brakes cannot be increased. The pressure to the front brakes will be increased by the master cylinder in accordance with the pedal effort applied to the brake pedal. From Reservoir To Front Brake 152CH29 Brake Actuator 1) Switching Solenoid Valves The control signals from the brake ECU cause the valves to open and close to switch the passages of the brake fluid. There are 3 switching solenoid valves (SMC1, SMC2, and SS) and they switch the passages to effect conventional brake control and ABS control. From Hydraulic Brake Booster To Wheel Cylinders From Master Cylinder To Front Wheel Cylinders To Rear Wheel Cylinders SMC1 and SMC2 SS 182CH49 113 CHASSIS – BRAKES 2) ABS Solenoid Valves The control signals from the brake ECU cause the valves to open and close to switch the passages of the brake fluid. There are 2 (pressure holding valve, pressure reduction valve) ABS solenoid valves provided. The pressure increases if no current is applied to either valve. The pressure is held if current is applied only to the pressure holding valve. The pressure decreases if current is applied to both the pressure holding valve and pressure reduction valve. To effect control independently to the front wheels, simultaneously to both rear wheels, 6 solenoid valves are provided. To Wheel Cylinder From Hydraulic Brake Booster Pressure Holding Valve (SFRH, SFLH, SRrH) From Wheel To ReserCylinder voir Tank Pressure Reduction Valve (SFRR, SFLR, SRrR) From Hydraulic Brake Booster Pressure Holding Valve From Wheel Cylinder To Wheel Cylinder Pressure Reduction Valve Increase Holding To Reservoir Tank Decrease 182CH50 3) Linear Solenoid Valves The control signals from the brake ECU cause the valves to open and close to regulate the volume of the brake fluid that flows into the wheel cylinders. There are 2 types of linear solenoids, the SLA for pressure increase and the SLR for pressure decrease, and they regulate the wheel cylinder pressure in accordance with the fluctuations in the regenerative brake force. In addition, the SLA contains a relief function to provide hydraulic pressure to the wheel cylinders in the event of a brake ECU failure. To Wheel Cylinders From Hydraulic Brake Booster SLA From Wheel Cylinders To Built-In Reservoir SLR 182CH51 114 CHASSIS – BRAKES 4) Stroke Simulator The stroke simulator generates a pedal stroke in accordance with the driver’s pedal effort during braking. Containing 2 types of coil springs with different spring constants, the stroke simulator provides pedal stroke characteristics in 2 stages in relation to the master cylinder pressure. From Master Cylinder Stroke Simulator Full Stroke Spring for 1st Stage Spring for 2nd Stage 2nd Stage Spring Characteristics Pedal Stroke To Reservoir 1st Stage + 2nd Stage Spring Characteristics Master Cylinder Hydraulic Pressure 182CH52 5) Reservoir Temporarily stores the brake fluid to absorb the pressure when regulating the wheel cylinder pressure. From wheel Cylinder (SLR) 182CH53 6) Pressure Sensors Mounted on the brake actuator, the pressure sensor linearly detects the pressure that is generated in the master cylinder, regulator, and the front and rear wheel cylinders and outputs them to brake ECU. 182CH54 115 CHASSIS – BRAKES Brake ECU 1) General Based on the signals received from the sensors the communication it maintains with the HV ECU, the brake ECU effects conventional brake control, ABS with EBD control, and regenerative brake cooperative control. Brake Actuator Solenoid Relay Speed Sensors Combination Meter ABS Solenoid Valves Switching Solenoid Valve Speedometer Linear Solenoid Valve ABS Warning Light Brake System Warning Light Master Cylinder Pressure Sensor Regulator Pressure Sensor Brake Warning Buzzer Front Wheel Pressure Sensor Brake ECU Rear Wheel Pressure Sensor Stop Light Switch ECM Hydraulic Brake Booster Motor Relay HV ECU Pump Motor High Pressure Switch Low Pressure Switch Inverter Battery ECU Reservoir Level Switch 182CH55 2) Fail Safe If a malfunction occurs in the brake ECU, in the input signals from the sensors, or in actuator system, this function prohibits the current from flowing to the brake actuator. As a result, the solenoids in the brake actuator turn off, enabling the braking force of the hydraulic brake to take effect. Furthermore, by illuminating the ABS warning light or the brake system warning light, this function alerts the driver that a malfunction exists in the system. Only if the regenerative brake system cannot be used, such as in the case of a malfunction in the communication with the HV ECU, this function switches controls to enable the hydraulic brake to generate the entire brake force. 3) Warning Light Check Function The ABS warning light and brake system warning light turns on for about 3 seconds after the ignition switch is turned on to check the circuit. 116 CHASSIS – BRAKES 4) Self-Diagnosis If the brake ECU detects a malfunction in the brake system, the ABS warning light and brake system warning light will light up and alert the driver that a malfunction has occurred. The ECU will also store the codes of malfunctions. See the 2001 Prius Repair Manual (Pub. No. RM778U) for the DTC (Diagnostic Trouble Code) check method, DTC and DTC clearance. Brake System Control 1) ABS with EBD control a. General The EBD control utilizes ABS, realizing the proper brake force distribution between front and rear wheels in accordance with the driving conditions. In addition, during cornering braking, it also controls the brake forces of right and left front wheels, helping to maintain the vehicle stability. The distribution of the brake force is performed under electrical control of the brake ECU, which precisely controls the brake force in accordance with the vehicle’s driving conditions. b. Operation Based on the signals received from the 4 wheel speed sensors, the brake ECU calculates each wheel speed and deceleration, and checks wheel slipping condition. And according to the slipping condition, the ECU controls the solenoid valves in order to adjust the fluid pressure of each wheel cylinder in the following three modes: pressure reduction, pressure holding and pressure increase modes. Not Activated Normal Braking Activated Pressure Increase Mode – – Pressure Holding Mode Pressure Reduction Mode Port A Hydraulic Circuit Pressure Holding Valve To Wheel Cylinder To Reservoir and Pump Port B Pressure Preduction Valve From Wheel Cylinder 182CH79 182CH80 182CH81 Pressure Holding Valve (Port A) OFF (Open) ON (Close) ON (Close) Pressure Reduction Valve (Port B) OFF (Close) OFF (Close) ON (Open) Wheel Cylinder Pressure Increase Hold Reduction 117 CHASSIS – BRAKES
Sample of ABS control  To Reservoir Tank From Master Cylinder Pressure Sensor Pressure Sensor SLR SLA Stroke Simulator ON OFF SS SMC1 ON SMC2 ON ON Reservoir Pressure Sensor Pressure Sensor SRrH ON SRrR ON SFRH ON SFRR OFF SFLH OFF SFLR OFF P & B Valve Rear Wheel Cylinders Front Wheel Cylinders 182CH57 118 CHASSIS – BRAKES 2) Regenerative Brake Cooperative Control a. General The regenerative brake cooperative control uses the switching valves and linear solenoid valves to regulate the hydraulic pressure that is supplied to the wheel cylinders. It also operates cooperatively with the regenerative braking force that is generated in the MG2 in accordance with the master cylinder pressure. b. Apportioning of the Brake Force The apportioning of the brake force between the hydraulic brake and the regenerative brake varies by the vehicle speed and time. The apportioning of the brake force between the hydraulic brake and the regenerative brake is controlled so that the total brake force of the hydraulic brake and the regenerative brake matches the brake force that the driver requires.
Imagery Drawing  Regenerative Braking Force Driver’s Demand Hydraulic Braking Force Driver’s Demand Hydraulic Regenerative Braking Force Braking Force Braking Force Braking Force Battery Acceptance Capacity Vehicle Speed Changes in Regenerative Braking Force Time Changes in Braking Force Apportionment 182CH58 c. Operation Regenerative brake cooperative control is executed when the vehicle is driven in the shift position “D” or “B”. The master cylinder pressure that is generated when the driver presses on the brake pedal is detected by the pressure sensor, and the brake ECU calculates the brake force request factor. A portion of the brake force request factor is transmitted to the HV ECU in the form of a regenerative brake activation request factor. The HV ECU executes generative braking by commanding the electric motor to generate negative torque. The brake ECU controls the opening of the linear solenoid valves, which are used for increasing/decreasing the hydraulic pressure, to regulate the wheel cylinder hydraulic pressure in relation to the master cylinder hydraulic pressure, thus compensating for the brake force that is not provided sufficiently by the regenerative brake. While the regenerative brake cooperative control is being prohibited due to an abnormality in the system, or when the shift lever is in a position other than D or B, the regenerative braking force is not generated. At this time, only the hydraulic braking force is applied by turning ON (opening) the linear solenoid valve SLA and turning OFF (closing) the SLR. 119 CHASSIS – BRAKES i) Regenerative Brake Cooperative Control Accumulator Reservoir Tank Pump Motor Pressure Switches Relief Valve Master Cylinder Pressure Sensor Pressure Sensor SLR SLA Stroke Simulator ON ON Reservoir SMC1 ON SS ON SMC2 ON Pressure Sensor Pressure Sensor SRrH OFF SRrR OFF SFRH OFF SFRR OFF SFLH OFF SFLR OFF P & B Valve Rear Wheel Cylinders Front Wheel Cylinders 182CH59 120 CHASSIS – BRAKES ii) Without Regenerative Brake Cooperative Control (Hydraulic Brake Only) Accumulator Reservoir Tank Pump Motor Pressure Switches Relief Valve Master Cylinder Pressure Sensor Pressure Sensor SLA SLR Stroke Simulator ON OFF Reservoir Pressure Sensor SRrH OFF SRrR OFF SS ON SMC1 ON SMC2 ON Pressure Sensor SFRH OFF SFRR OFF SFLH OFF SFLR OFF P & B Valve Rear Wheel Cylinders Front Wheel Cylinders 182CH60 121 CHASSIS – BRAKES 3) Fail-Safe Control If a malfunction occurs in the brake ECU, in the input signals from the sensors, or in the actuator system, this function prohibits the current from flowing to the brake actuator. As a result, the solenoids in the brake actuator turn off, enabling the braking force of the hydraulic brake to take effect. The relief function is provided in order to ensure the proper wheel cylinder hydraulic pressure even if the linear solenoid valve SLA is OFF (closed). Only if the regenerative brake system cannot be used, such as in the case of a malfunction in the communication with the HV ECU, this function switches controls to enable the hydraulic brake to generate the entire brake force. Accumulator Reservoir Tank Pump Motor Pressure Switches Relief Valve Master Cylinder Pressure Sensor Pressure Sensor SLA SLR OFF Stroke Simulator OFF Reservoir SS OFF SMC1 OFF SMC2 OFF Pressure Sensor Pressure Sensor SRrH OFF SRrR OFF SFRH OFF SFRR OFF SFLH OFF SFLR OFF P & B Valve Rear Wheel Cylinders Front Wheel Cylinders 182CH61 122 CHASSIS – STEERING STEERING DESCRIPTION  A vehicle-speed sensing type EMPS (Electric Motor-assisted Power Steering) has been adopted. The EMPS uses the EMPS ECU to control a DC motor that is mounted on the steering gear in accordance with the signals received from various sensors to provide power assist to the steering effort.  A rack and pinion type steering gear and a stepless tilt steering have been adopted.  The steering column has adopted an energy absorbing mechanism that uses energy absorbing plate. 182CH62
Specifications  16.4
18.3 Gear Ratio (Overall) No. of Turns Lock to Lock Rack Stroke 3.99 mm (in.) 149.6 (5.89) 123 CHASSIS – STEERING EMPS (Electric Motor-assisted Power Steering) 1. General In accordance with sensor information such as that provided by the rear wheel speed sensors, the torque sensor that is mounted on the steering gear, and the EMPS ECU determines the direction and the force of the power assist and actuates the DC motor that is mounted on the steering gear to provide power assist to the steering effort. The EMPS in the Prius the following features:  This system can provide power assist even when the engine is stopped.  This system offers excellent fuel economy characteristics because power assist is provided by the DC motor that is mounted on the steering gear, and this motor consumes energy only when power assist is required.  Unlike the conventional hydraulic power steering system, this system excels in serviceability because it does not require pipes or the power steering fluid.
System Diagram  Rear Wheel Speed Sensors DLC3 Brake ECU Torque Sensor Signal 1 Torque Sensor Signal 2 Meter ECU EMPS ECU Gateway ECU Display ECU Multi-information Display 182CH68 124 CHASSIS – STEERING 2. Layout of Main Components Meter ECU EMPS ECU Multi-information Display Rear Wheel Speed Sensors and Rotors Relay Brake ECU DC Motor 182CH69 3. Function of Main Components Components St i Steering Gear Function Torque Sensor Detects the twist of the torsion bar, converts the torque that is applied to the torsion bar into an electrical signal, and outputs this signal to the ECU. DC Motor Generates power assist in accordance with a signal received from the EMPS ECU. Reduction Mechanism Reduces the rotation of the DC motor and transmits it to the pinion shaft. EMPS ECU Actuates the DC motor mounted on the steering gear for providing power assist, based on the signals received from various sensors and the rear wheel speed signal. Meter ECU Outputs a signal for displaying the PS warning on the center display in case of a malfunction in the system. Brake ECU Rear wheel speed signals are outputted to EMPS ECU. Relay Supplies power to the DC motor for power assist. Multi-information Display Displays the PS warning in case of a malfunction in the system. 125 CHASSIS – STEERING 4. Construction and Operation of Main Components Steering Gear 1) General The steering gear consists of the rack and pinion, DC motor, reduction mechanism, and torque sensor. The front suspension components have been optimized to reduce the load on the DC motor. Also, the components have been optimally allocated to ensure ample rack travel and wheel turning angle, resulting in excellent cornering performance. Torque Sensor DC Motor Rack and Pinion Reduction Mechanism 182CH70 2) DC Motor The DC motor is mounted on the gear housing. The DC motor consists of the motor shaft that is integrated with the hypoid pinion to transmit the torque that has been generated by the drive force of DC motor to the pinion shaft, the rotor and stator. Motor Shaft Stator Rotor 3) Reduction Mechanism 182CH71 A reduction mechanism that transmits the rotation of the motor to the pinion shaft has been mounted on the steering gear. The reduction mechanism consists of the ring gear that is secured to the pinion shaft and the pinion gear that is integrated with the motor shaft. The power assist of the motor is transmitted by the reduction mechanism to the pinion shaft, which provides power assist to the steering effort. Pinion Gear Motor Shaft DC Motor Pinion Shaft Ring Gear 182CH72 126 CHASSIS – STEERING 4) Torque Sensor A torque sensor that detects the torque that is input by the steering wheel has been mounted on the pinion shaft. The torque sensor has been integrated with the pinion shaft, and the pinion shaft’s input and output shafts are linked via the torsion bar. Resistors for the torque sensor are mounted on the input shaft of the pinion shaft, and contacts for the torque sensor are mounted on the output shaft of the pinion shaft. Operating the steering wheel causes the torsion bar to twist, creating a displacement between the pinnion shaft’s input and output. Two systems of torque sensors detect this displacement in the form of voltage changes, which are then output to the EMPS ECU. Resistor 1 Upward Resistor 2 Torque Sensor Resistor Contact 1 Contacts Contact 2 Downward 182CH73 i) Straightline Driving If the vehicle is driven straight and the driver does not turn the steering, torque is not generated in the pinion shaft’s input shaft. Thus, the torsion bar does not twist, and no changes in resistance occur in the torque sensor. Resistor Basic Position Contact Straightline 182CH74 127 CHASSIS – STEERING ii) Steering to the right When the driver turns the steering to the right, the steering torque is transmitted to the pinion shaft’s input shaft, causing the input shaft to rotate. Because the reaction force of the ground surface acts on the rack bar, the torsion bar that links the input shaft and the pinion twists until a torque that equalizes with the reaction force is generated. Thus, a relative displacement is created between the resistor that is secured onto the input shaft and the contact that is secured onto the pinion shaft’s output shaft. As a result, the resistance changes, causing the torque sensor’s outputs 1 and 2 to change as shown in the right diagram. The EMPS ECU uses this voltage difference to calculate the power assist torque to drive the DC motor, thus generating a power assist force in the pinion shaft via the reduction mechanism. Twist Angle Basic Position Cornering Torque [V] 182CH95 Voltage difference between outputs 1 and 2 during straight line driving (0) Voltage Torque Sensor 2 Torque Sensor 1 – Right Turn 0 + Left Turn 182CH76 iii) Steering Hold Condition The torsion bar shift to a position in which the sum of the driver’s steering torque and the motor’s assist torque equalizes with the reaction force of the ground surface in order to maintain the steering holding condition. EMPS ECU 1) EMPS Control The EMPS ECU receives signals from various sensors, judges the current vehicle condition, and determines the assist ampere to be applied to the DC motor accordingly. 2) Self-Diagnosis If the EMPS ECU detects a malfunction in the EMPS system, the warning light that corresponds to the function in which the malfunction has been detected lights up to alert the driver of the malfunction. The EMPS ECU will also store the codes of the malfunctions. The DTCs (Diagnostic Trouble Codes) can be accessed through the use of a hand-held tester. For details, see the 2001 Prius Repair Manual (Pub. No. RM778U). 3) Fail-Safe If the EMPS ECU detects a malfunction in the EMPS system, the system basically turns OFF the power to prohibit power assist. As a result, the EMPS system operates the same way as manual steering. However, depending on the location in which the malfunction occurred, power assist may be provided by reducing the power assist amperage or by fixing the amount of power assist without relying on the vehicle speed. 128 CHASSIS – STEERING TILT STEERING The tilt mechanism consists of a tilt lever, column tube, breakaway bracket, tilt lever lock bolt, tilt steering adjusting nut. When the tilt mechanism is in its locked state, operating the tilt lever downward causes the tilt steering adjusting nut to loosen (because the tilt lever lock bolt has left-handed screw threads). When the tilt mechanism is in its free state, operating the tilt lever upward causes the tilt steering adjusting nut to tighten. Stepless A A Tilt Lever 182CH63
A – A Cross Section  Column Tube Breakaway Bracket Tilt Steering Adjusting Nut Tilt Lever Lock Bolt Tilt Lever Free Lock 182CH64 182CH65 129 CHASSIS – STEERING ENERGY ABSORBING MECHANISM The energy absorbing mechanism in the steering column consists of a lower bracket, breakaway bracket, energy absorbing plate and a contractile main shaft. The steering column is mounted onto the instrument panel reinforcement via a lower bracket and breakaway bracket which is supported via a capsule and energy absorbing plate. The steering column and the steering gear box are connected with a contractile intermediate shaft. Operational examples of this mechanism are follows. When the steering gear box moves during a collision (primary collision), the main shaft and the intermediate shaft contract, thus reduce the chance that the steering column and the steering wheel protrude into the cabin. When an impact is transmitted to the steering wheel in a collision (secondary collision), the steering wheel and the driver airbag help absorb the impact. In addition, the breakaway bracket and the lower bracket separate, causing the entire steering column to move forward. At this time, the energy absorbing plate becomes deformed to help absorb the impact of the secondary collision. Instrument Panel Reinforcement Instrument Panel Reinforcement Main Shaft Energy Absorbing Plate Breakaway Bracket Before Collision 182CH66 Secondary Collision Detach Deform Contract Primary Collision After Collision 182CH67 130 BODY – BODY STRUCTURE BODY BODY STRUCTURE DESCRIPTION The Prius has adopted a body construction that achieves both high rigidity and safety. LIGHTWEIGHT AND HIGHLY RIGID BODY 1. High Strength Sheet Steel High strength sheet steel has been used in order to ensure body rigidity and realize a lightweight body. : High Strength Sheet Steel 182BO01 131 BODY – BODY STRUCTURE 2. Body Shell
The joining construction (A-A cross section) of the cowl side panel, front pillar, and the instrument panel reinforcement has been optimized to restrain the generation of vibrations.
By joining the under body and the front pillar with a pillar brace (B-B cross section), as well as the upper end of the front pillar with the roof header (C-C cross section), the generation of vibrations has been restrained.
By providing a gusset (D) in the quarter wheel house and a reinforcement (E) in the upper back panel, the generation of vibrations in the rear body area has been restrained. (E) (D) C C C – C Cross Section A A B A – A Cross Section B B – B Cross Section 182BO02 132 BODY – BODY STRUCTURE SAFETY FEATURES 1. Impact Absorbing Structure General The impact absorbing structure of the Prius provides a body construction that can effectively helps absorb the energy of impact in the event of a front, or side collision. Also, it realizes a high level of occupant protection performance through the use of reinforcements and members that help to minimize cabin deformation. Construction 1) Impact Absorbing Structure for Front Collision In conjunction with the high level of impact absorbing structure for a front collision, the front bumper reinforcement, the side members, the reinforcements and members that surround the cabin have been optimally allocated. Accordingly, the frameworks of the underbody and cabin help to absorb and dissipate the impact energy efficiently, and to realize the minimized cabin deformation, in case of a front collision.
Impact Absorbing Structure for Front Collision  Front Impact Energy 182BO03 133 BODY – BODY STRUCTURE 2) Impact Absorbing Structure for Side Collision  Impact energy of a side collision directed to the cabin area is dispersed throughout the body via pillar reinforcements, side impact protection beams, floor cross members, thus helping minimize the impact energy finally directed to the cabin. In addition, the body is made reinforced joints and high strength sheet steel, in order to help maintain the maximum preservation of the cabin space. And, in order to make the door energy absorbent, a closed cross section configuration is provided at the belt line area of the front and rear doors.  By providing an energy absorbing urethane pad in the front door panel and an energy absorbing material in the door panel and the center pillar garnish, the impact of a collision can be dampened.  A head impact protection structure has been adopted. With this type of construction, if the occupant’s head hits against the roof side rail and pillar in reaction to a collision, the inner panel of the roof side rail and pillar collapses to help reduce the impact.
Impact Absorbing Structure for Side Collision  Energy Absorbing Material Energy Absorbing Urethane Pad Side Impact Protection Beams Side Impact Protection Beam Side Impact Energy 182BO04
Head Impact Protection Structure  : Energy Absorbing Rib : Aluminum Energy Absorbing Material 182BO05 134 BODY – RUST-RESISTANT BODY
RUST-RESISTANT BODY 1. General Rust-resistant performance is enhanced by extensive use of anti-corrosion sheet steel and an anti-corrosion treatment by applying wax, sealer and anti-chipping paint to easily corroded parts such as the hoods, doors and rocker panels. 2. Anti-Corrosion Sheet Steel Anti-corrosion sheet steel is used in all areas other than the roof and interior parts. : Anti-Corrosion Sheet Steel 182BO06 135 BODY – RUST-RESISTANT BODY 3. Wax and Sealer Wax and sealer are applied to the hemmed portions of the hoods, door panels, rocker panel and luggage compartment door to improve rust-resistant performance. 4. Under Coat PVC (Polyvinyl Chloride) coating is applied to the under side of the body. The bottom side of the cowl panel, the fender apron and other parts which are subject to damage by stone chipping. : Edge Seal : PVC Coating Area 182BO07 5. Anti-Chipping Application Anti-chipping paint and PVC chipping primer are applied to the lower quarter panel area, lower door panel area, front hood area and the rocker panel area to protect them from stone chipping. : Anti-Chipping Paint : PVC Chipping Primer 182BO08 136 BODY – LOW VIBRATION AND LOW NOISE BODY LOW VIBRATION AND LOW NOISE BODY 1. General Effective application of vibration damping and noise suppresant materials reduces engine and road noise. 2. Sound Absorbing and Vibration Damping Materials
Adoption of the dash panel silencer made the reduction of the engine and road noise and improved the quietness in the compartment.
Foamed urethane sponge, foamed seal material, felt and roof silencer pad are applied onto the roof panel and pillars to reduce wind and road noise.
The adoption of the floor silencer realized the reduction of the engine and road noise. Also, the adoption of RSPP (Recycled Sound Proof Products) for raw material realized the improvement of recylability. : Roof Silenser Pad Foamed Urethane : Sponge : Foamed Seal Material : Felt Dash Panel Silencer 182BO09 Floor Silencer (RSPP) 182BO10 137 BODY – AERODYNAMICS AERODYNAMICS DESCRIPTION To improve aerodynamic performance, the following measures have been taken.
The shapes of the front pillar, outside rear view mirror, and the front windshield glass have been optimized to achieve a smooth air flow.
The height and the shape of the front bumper have been optimized in order to rectify the airflow under the floor and along the body sides.
The shapes of the engine undercover, fuel tank bottom surface, and the rear floor bottom surface have been optimized to achieve a smooth underbody air flow.
A front and rear fairings are provided to smooth out the airflow around the tires and reduce the air resistance while the vehicle is in motion. 182BO12 Front Fairing Rear Fairing 182BO13 138 BODY – ENHANCEMENT OF PRODUCT APPEAL ENHANCEMENT OF PRODUCT APPEAL INTERNAL TRUNK RELEASE HANDLE An internal trunk release handle is included inside the trunk in case a person inadvertently locks himself within the trunk and needs to free himself. The handle is made of phosphorescent so that it is visible in the trunk for a while even after the trunk has been closed. Phosphorescent 182BO14 SEAT
CRS (Child Restraint System) lower anchorage for securing child seats, which complies with FMVSS225, has been provided behind the seat cushion of both outer rear seats.
Three CRS anchor brackets for securing a child seat have been provided above the package tray trim. CRS Anchor Bracket A CRS Anchor Bracket B CRS Lower Anchorage B A Anchor Cover Package Tray Trim Seat Back Seat Cushion CRS Lower Anchorage A – A Cross Section B – B Cross Section 182BO15 139 BODY – ENHANCEMENT OF PRODUCT APPEAL SEAT BELT 1. General
The front seats are provided with an electrical sensing type seat belt pretensioner and a seat belt force limiter. In the beginning of a collision, the seat belt pretensioner instantly pulls up the seat belt thus providing the excellent belt’s effectiveness in restraining the occupant. When the impact of a collision causes the tension of the seat belt applied to the occupant to reach a predetermined level, the force limiter restrains the tension, thus controlling the force applied to the occupant’s chest area.
In accordance with the ignition signal from the airbag sensor assembly, the seat belt pretensioner activates simultaneously with the deployment of the SRS airbags for the driver and front passenger.
The passenger seats are provided with ALR (Automatic Locking Retractor)/ELR (Emergency Locking Retractor) seat belts. 2. Seat Belt Pretensioner General The pretensioner mechanism mainly consists of a rack, pinion gear, planetary gear, clutch mechanism, and a bobbin. During the deployment of this pretensioner mechanism, the gas pressure from the gas generator pushes the rack down and retracts the seat belt via the pinion gear, planetary gear, clutch mechanism, and bobbin. Gas Pressure from the Gas Generator Rack Bobbin Seat Belt Planetary Gear Clutch Mechanism Pinion Gear 182BO16 140 BODY – ENHANCEMENT OF PRODUCT APPEAL 3. Seat Belt Force Limiter The seat belt force limiter mainly consists of an energy absorbing shaft, lock sensor assembly, bobbin, and sleeve. When the seat belt is pulled out at a rate that exceeds the specified acceleration rate, the ELR (Emergency Locking Retractor) becomes activated, causing the lock sensor assembly to lock the energy absorbing shaft. Because the bobbin on which the seat belt is attached is secured to the energy absorbing shaft via the sleeve, the energy absorbing shaft becomes twisted. The twisting of the energy absorbing shaft causes the bobbin to rotate and the seat belt to be pulled out, thus maintaining the tension that is applied to the seat belt. Seat Belt Energy Absorbing Shaft Bobbin Sleeve Lock Sensor Assembly 174BO02 BODY ELECTRICAL – BATTERY AND MULTIPLEX COMMUNICATION SYSTEM 141 BODY ELECTRICAL AUXILIARY BATTERY DESCRIPTION All the body electrical systems and auxiliary equipment operate using the same 12 V battery used on ordinary gasoline engine vehicles. However, as the battery structure is different, Prius uses an exclusive battery. See page 42 in the THS (TOYOTA Hybrid System) section for details of the auxiliary battery structure. MULTIPLEX COMMUNICATION SYSTEM DESCRIPTION  A multiplex communication system has been adopted for body electrical system control and to achieve a slimmer wiring harnesses configuration.  BEAN (Body Electronics Area Network) has been adopted between the body ECU, ECM, meter ECU, air conditioning ECU, and the gateway ECU. Furthermore, AVC-LAN (Audio Visual CommunicationLocal Area Network) has been adopted between the display ECU and the audio components. The conversion of communication signals between BEAN and AVC-LAN is performed by the gateway ECU.  UART (Universal Asynchronous Receiver Transmitter), which performs unidirectional communication, has been adopted between the body ECU and the power window master switch.  A serial data link has been adopted between the body ECU and the door control receiver. In addition, a serial data link has been adopted between the ECM, HV ECU, brake ECU, and the battery ECU, which pertain to the control of the hybrid system.
System Diagram  Air Conditioning ECU Display ECU Brake ECU Gateway ECU Meter ECU HV ECU ECM Audio Components Body ECU Power Window Master Switch Door Control Receiver Battery ECU : BEAN : AVC-LAN : UART : Serial Data Link 182BE01 142 BODY ELECTRICAL – MULTIPLEX COMMUNICATION SYSTEM SYSTEM OPERATION 1. General The ECUs that pertain to the body electrical system perform the functions and system controls described below. Gateway ECU  Conversion of data between AVC-LAN and BEAN  Transmission of vehicle information to the display ECU, in order for it to be displayed on multi-information display Body ECU  Power window system control (Front, Rear passenger only)  Door lock control system control  Wireless door lock remote control system control  Theft deferrent system control  Daytime running light system control  Illuminated entry system control  Light auto turn-off system control  Seat belt warning system control  Key reminder system control  Diagnosis Meter ECU  Meter control  Illumination and flashing control of indicator and warning lights  Sounding control of warning buzzer Air Conditioning ECU Air Conditioning control ECM  Engine control  Diagnosis Display ECU  Transmission and reception associated with audio and visual functions BODY ELECTRICAL – MULTIPLEX COMMUNICATION SYSTEM 143 2. Gateway Function (Gateway ECU) This multiplex communication system has adopted BEAN (Body Electronics Area Network) between the body ECU, ECM, meter ECU, air conditioning ECU, and the gateway ECU, as well as AVC-LAN between the display ECU and the audio components. Because the data configuration differs between BEAN and AVCLAN, their data must be converted in order for them to exchange each other’s data. The conversion of communication data is performed by the gateway ECU. As a result, it has become possible for a single communication line to transmit various types of information. Display ECU CPU Gateway ECU CPU Body ECU AVC-LAN Transmission Reception Control AVC-LAN Transmission Reception Circuit AVC-LAN AVC-LAN Transmission Reception Circuit Conversion Control BEAN Transmission Reception Circuit Meter ECU BEAN Audio Components 182BE02 144 BODY ELECTRICAL – LIGHTING LIGHTING HEADLIGHTS The prius has newly adopted the multi-reflector headlights. Conventional headlights accomplish the dispersion and distribution of the light that is emitted by the bulbs through the lens cut pattern. However, with the multi-reflector type headlights, the light from the bulbs is dispersed and distributed through multiple parabolic shaped reflectors. As a result, the lens cut pattern is no longer provided in the center of the lens, thus realizing a clear look.
Light Distribution Diagram  Reflector (Multiple Parabolic Shape) Reflector (Rotating Parabolic Shape) Headlight Bulb Headlight Bulb Lens Cut Headlight Bulb Lens Lens Light Distribution Light Distribution 151LBE67 151LBE68 Conventional Headlight Multi-Reflector Type Headlight DAYTIME RUNNING LIGHT SYSTEM The daytime running light system is adopted for Canada model as standard and U.S.A. model as optional equipment. This system is designed to automatically activate the headlights (dimmed low beams) during the daytime to keep the car highly visible to other vehicles. This system is controlled by a semi-conductor relay circuit (daytime running light relay). Dimmer Relay From Battery Headlight Relay Parking Brake Switch H-LP DIM Daytime PKB Running Light Relay E HI DRL H From Battery LO HI LO No.4 Daytime Running Light Relay 182BE03 BODY ELECTRICAL – LIGHTING 145 ILLUMINATED ENTRY SYSTEM  When a door is unlocked through a key operation or transmitter operation, or if a door is opened or closed, the illuminated entry system turns ON the dome light. If the ignition switch is turned to the ACC or ON position or if all doors are locked during the 15 seconds in which this light are ON, they will immediately turn OFF.  This system is controlled by the body ECU. LIGHT AUTO TURN-OFF SYSTEM  When the ignition key is turned from ON or ACC to LOCK position and the driver’s door is opened with the taillights and headlights on, this system automatically turns them off.  This system is controlled by the body ECU. 146 BODY ELECTRICAL – METER METER COMBINATION METER 1. General
The combination meter is available as a digital display type. It is located at the upper center of the instrument panel to improve its visibility.
For this combination meter, a meter ECU that effects multiplex communication through the use of BEAN (Body Electronics Area Network) has been adopted.
The display of the speedometer can be switched between km/h and MPH readings by operating the km/hMPH selector switch located in the middle of the center cluster. Furthermore, the odo/trip meter can be switched between odometer and tripmeter readings by operating the odo/trip selector/reset switch located in the middle of the center cluster.
A “READY” light that informs the driver that the vehicle is ready to be driven has been adopted.
A master warning light that informs the driver if an abnormality occurs in either the EMPS (Electric Motorassisted Power Steering), HV batteries, or the THS (TOYOTA Hybrid System) has been adopted.
An output control warning light has been adopted to show the drop of power function due to the output drop of HV batteries.
For the purpose of making corrections in the calculation of the fuel level by the meter ECU, two inclination sensors that detect the vehicle’s longitudinal and latitudinal inclinations have been provided in the meter ECU. In addition, an outer ambient temperature sensor has been provided in the fuel tank to detect the temperature in the fuel tank. Master Warning Light “READY” Light Output Control Warning Light U.S.A. Model 182BE04 Canada Model 182BE16 147 BODY ELECTRICAL – METER 2. Construction and Operation Speedometer
The speedometer is displayed digitally through the VFD (Vacuum Fluorescent Display). It can be switched between the km/h and MPH readings by operating the km/hMPH selector switch located in the middle of the center cluster.
The vehicle speed signal, which originates at the speed sensor that is installed in the hybrid transaxle, travels via the HV ECU and ECM (BEAN) and is received by the meter ECU. Km/h-MPH Selector Switch 182BE05 Odo/Trip Meter Similar to the speedometer, the odo/trip meter is displayed digitally through the VFD (Vacuum Fluorescent Display). By operating the odo/trip selector/reset switch located in the middle of the center cluster, its display can be switched in the following sequence: odometer
trip meter A
trip meter B. While trip meter A or B is displayed, pressing the odo/trip selector/reset switch 0.8 seconds or longer causes the driven distance displayed by the current trip mode to revert to 0.0 mile or 0.0 km. The trip meter will resume measuring the distance at the moment the odo/trip selector/reset switch is released. Odo Meter Trip Meter A Trip Meter B Odo/Trip Selector/Reset Switch 182BE06 148 BODY ELECTRICAL – METER Fuel Gauge For the purpose of correcting the calculation of the fuel level by the meter ECU, two inclination sensors that detect the vehicle’s longitudinal and latitudinal inclinations have been provided in the meter ECU, and an ambient temperature sensor has been provided in the fuel tank to detect the temperature in the fuel tank. The fuel level is calculated by the meter ECU in accordance with the signals of the sender gauge located in the sub tank that have been received via the body ECU, and the fuel injection signals received from the ECM. At this time, corrections are made by the signals from the inclination sensors that detect the vehicle’s longitudinal and latitudinal inclinations and the ambient temperature sensor that detects the temperature in the fuel tank. Combination Meter Sender Gauge Fuel Injection Signal Meter ECU ECM Sender Gauge Signal Body ECU Inclination Sensors Fuel Tank Temperature Signal Ambient Temperature Sensor Sender Gauge Signal Fuel Sender Gauge Main Tank Sub Tank Fuel Pump 182BE07 149 BODY ELECTRICAL – METER “READY” Light When the shift position is P, turning the ignition switch to START causes the “READY” light to flash and enables the vehicle to be driven. Then, this indicator illuminates and the buzzer sounds simultaneously. Flashes when the ignition switch is turned to START Illuminates when the vehicle is ready to be driven 182BE08 Service Tip If the indicator does not illuminate, the vehicle cannot be driven because one of the driving prohibition conditions listed below applies.
Service plug disconnected.
Inverter unit cover is left open.
Hybrid system abnormality.
HV ECU has detected a collision.
Driving prohibition condition due to overload on MG1, MG2 or inverter. Master Warning Light A master warning light that informs the driver if an abnormality occurs in either the EMPS, HV batteries, or the THS has been adopted. If an abnormality occurs in the system, the master warning light illuminates and the multi-information display shows the warning items. For details, see page 178. Output Control Warning Light An output control warning light has been adopted to show the drop of power function due to the output drop of HV batteries. This warning light comes on when the temperature of HV batteries is higher or lower than that of specified range, or when SOC (State of Charge) is lower than the specified value with the shift position in R range. When this warning light comes on, avoid sudden acceleration and drive carefully. 150 BODY ELECTRICAL – WIPER WIPER TELESCOPIC WIPER 1. General
The telescopic wiper has been adopted.
The telescopic wiper consists of a wiper arm for the front passenger side that wipes telescopically from the stopped position to the upper return position in order to enlarge the wiping area. Wiping area enlarged through the telescopic movement 182BE10 182BE09 Telescopic Type Conventional Type 2. Construction The telescopic wiper mainly consists of a driver wiper arm, passenger wiper arm, main lever, idle lever, wiper link and wiper motor. Idle Lever Passenger Wiper Arm Driver Wiper Arm Wiper Link Wiper Motor Rotation Diameter Pivot Pivot Wiper Link Main Lever 182BE11 Pivot 151 BODY ELECTRICAL – WIPER 3. Operation
With the rotation of the wiper motor, the wiper link for driving wiper will operate and connection point P1 with the main lever will move toward the arrow mark by the influence of the wiper link with a pivot as a supporting point. With this, the connection point P2 between the wiper arm and the idle lever becomes the supporting point of the pry and starts wiping by holding the arm upward. P1 P2 Wiper Arm Main Lever Direction of Rotation of Wiper Motor Pivot Idle Lever Pivot Wiper Link 182BE12
In addition, when the wiper motor rotates, P1 and P2 will move toward the arrow mark. Then, the wiper arm with P3 as a supporting point will rise by the influence of the idle arm as if expanding upward to the left. With this, it enables to wipe wider range. Wiper Arm P2 Direction of Rotation of Wiper Motor P3 P1 Idle Arm 182BE13
When the wiper motor rotates more, P1 and P2 will move toward the arrow mark. The wiper arm with P2 as a supporting point will move toward contracting direction and wipe further to the upper reversal position. Wiper Arm P2 Direction of Rotation of Wiper Motor P1 182BE14 152 BODY ELECTRICAL – AIR CONDITIONING AIR CONDITIONING DESCRIPTION The air conditioning system in the Prius has the following features:  Both heating and demisting performances are realized by adopting performances are realized by adopting the 2-way flow heater type air conditioning unit.  A multi-tank, super-slim structure evaporator has been adopted.  An automatic air conditioning system which provides enhanced air conditioning comfort according to the occupant’s senses has been adopted.  A semi-center location air conditioning unit, in which the evaporator and heater core are placed in the vehicle’s longitudinal direction, has been adopted.  A compact, high-performance scroll compressor with oil separator has been adopted.  The heat exchange efficiency has been improved through the adoption of the sub-cool condenser. This condenser is integrated with the radiator to minimize the space they occupy in the engine compartment.  A compact, lightweight, and highly efficient straight flow (full-path flow) aluminium heater core has been adopted. This heater core is integrated with a PTC (Positive Temperature Coefficient) heater, which excels in heating performance.  PTC heaters have been provided in the air duct at the footwell outlet in front of the air conditioning unit. However, air conditioning without the PTC heaters is offered as an option on the U.S.A. models.  An electrical water pump with a bypass valve that provides a stable heater performance even if the engine is stopped due to a function of the THS (TOYOTA Hybrid System) has been adopted.  A clean air filter that excels in removing pollen and dust is standard equipment. 153 BODY ELECTRICAL – AIR CONDITIONING
Performance  Item Heat Output Performance W 5300 m3 /h 330 Power Consumption W 170 Heater Core Integrated PTC Heater Heat Output W 330 (165 x 2) PIC Heater*1 Heat Output W 165 x 2 Heat Output W 4200*2 Air Flow Volume Heater Air Conditioning g Air Flow Volume Power Consumption m3 /h 450 W 200 *1: U.S.A. Cold Area Specification Model and Canada Model *2: When the compressor is at 1,800 rpm
Specifications  Ventilation and Heater Heater Core Item Specifications Type Straight Flow (Full-path Flow) Size WxHxL mm (in.) 216.9 x 140 x 27 (8.5 x 5.5 x 1.1) Fin Pitch mm (in.) 1.8 (0.07) Motor Type Blower Fan Size Dia. x H S70F-13T mm (in.) Air Conditioning Compressor *: With the radiator Internal Air 150 x 36 (5.9 x 1.4) Size WxHxL mm (in.) 600 x 349.8 x 37.5* (23.6 x 13.8 x 1.5) Fin Pitch mm (in.) 2.8 (0.11) Drawn Cup (Multi-tank, Super Slim Structure) Type Evaporator 132 x 41 (5.2 x 1.6) Multi-Flow Type (Sub-Cool Type) Type Condenser External Air Size WxHxL mm (in.) 253.2 x 215 x 58 (10.0 x 8.5 x 2.3) Fin Pitch mm (in.) 3.5 (0.14) Type SCS06 154 BODY ELECTRICAL – AIR CONDITIONING CONSTRUCTION AND OPERATION 1. Air Conditioning Unit Air Conditioning Assembly 1) General  A semi-center location air conditioning unit, in which the multi tank type evaporator and straight flow heater core are placed in the vehicle’s longitudinal direction, has been adopted.  Both heating and demisting performances are realized by adopting the 2-way flow heater type air conditioning unit. This unit, which introduces external air and internal air simultaneously, discharges warm internal air to the footwell area, and the fresh, dry external air to the upper area. Thus, it realizes both excellent heating performance and demisting performance. Fresh, dry external air to the upper area External Air Internal Air Warm internal air to the footwell area 182BE15 2) Construction A partition plate divides the inside of the air conditioning unit into two parts, the external air passage, and the internal air passage. Thus, by controlling the external air door and the internal air door separately, the external air and internal air are introduced into the cabin in the following three modes: fresh-air mode, recirculation mode, and fresh-air/recirculation (2-way flow) mode. Internal External Door External Air Internal Air DEF FACE Mode Door Internal Air Evaporator Air Mix Door Heater Core FOOT and Rr FOOT External Air Internal Air 181BE38 Airflow During 2-way Flow Control 155 BODY ELECTRICAL – AIR CONDITIONING 3) 2-Way Flow (Fresh-air/Recirculation) Mode When all the conditions listed below are met, the external air door, internal air door, which are controlled by the air conditioning ECU, are switched to the 2-way flow mode.  External air mode in the selected state  Blower switch in the ON state (except OFF)  Tentative air mix damper opening angle is above the specified value. (MAX HOT)  Mode select switch in either FOOT or FOOT/DEF state Heater Core and PTC Heater 1) General  A compact, lightweight, and highly efficient straight flow (full-path flow) aluminum heater core has been adopted. New (Straight Flow) Previous (U-turn Flow) 152BE21 152BE22  The 2 PTC (Positive Temperature Coefficient) heaters have been built into the heater core. PTC Heaters Insulation Film PTC Element Electrode 165BE18 156 BODY ELECTRICAL – AIR CONDITIONING  PTC heaters have been provided in the air duct at the footwell outlet in front of the air conditioning unit. However, air conditioning without the PTC heaters is offered as an option on the U.S.A. models. This PTC heater, which is a honeycombshaped PTC thermistor, directly warms the air that flows in the duct. PTC Heaters 182BE17
Wiring Diagram  Ignition Switch ALT HTR AM1 Ambient Temperature Sensor ECM PS HTR1 PTC HTR1 PTC HTR2 Engine Coolant Temperature Sensor IG MAIN MPX HTR0 HTR2 Battery Body ECU Air Conditioning ECU IDH Converter GND Switch Signals from Heater Control Panel Heater Core Integrated PTC Heater PTC Heaters 182BE18 BODY ELECTRICAL – AIR CONDITIONING 157 2) Operation a. Heater Core Integrated PTC Heater Model The heater turns ON when all the conditions listed below have been met. i) Outlet is in the DEF mode:  Coolant temperature is below the specified value.  Ambient temperature is below the specified value.  Converter’s PTC heater prohibition signal is OFF. ii) Outlet is in the FOOT or FOOT/DEF mode:  Coolant temperature is below the specified value.  Tentative air mix damper opening angle is above the specified value. (MAX HOT)  Converter’s PTC heater prohibition signal is OFF. b. Heater Core Integrated PTC Heater and PTC Heater Model In the case of the heater core integrated PTC heater and PTC heater model, the conditions under which the heater core integrated PTC heater operates are the same as those for the heater core integrated PTC heater model described above. Furthermore, in the heater core integrated PTC heater and PTC heater model, the PTC heater turns ON when all the conditions listed below have been met.  Outlet is in the FOOT or FOOT/DEF mode.  Blower switch in the ON state.  Coolant temperature is below the specified value.  Tentative air mix damper opening angle is above the specified value. (MAX HOT)  Converter’s PTC heater prohibition signal is OFF. 158 BODY ELECTRICAL – AIR CONDITIONING Evaporator By placing the tanks at the top and the bottom of the evaporator unit and by adopting an inner fin construction, the heat exchanging efficiency has been improved and the evaporator unit’s temperature distribution has been made more uniform. As a result, it has become possible to realize a thinner evaporator construction. Furthermore, the evaporator body has been coated with a type of resin that contains an antibacterial agent in order to minimize the source of foul odor and the propagation of bacteria. Antibacterial Agent Nylon Layer Chromate Layer Aluminum Matrix Inner Fin 163BE17 2. Condenser The Prius has adopted sub-cool condenser in which a multi-flow condenser (consisting of two cooling portions: a condensing portion and a super-cooling portion) and a gas-liquid separator (modulator) have been integrated. This condenser has adopted the sub-cool cycle for its cooling cycle system to improve the heat exchanging efficiency. This condenser is integrated with the radiator to minimize the space they occupy in the engine compartment. For details, see page 54 in the Engine Cooling System Section. Sub-Cool Cycle In the sub-cool cycle of the sub-cool condenser that has been adopted, after the refrigerant passes through the condensing portion of the condenser, both the liquid refrigerant and the gaseous refrigerant that could not be liquefied are cooled again in the super-cooling portion. Thus, the refrigerant is sent to the evaporator in an almost completely liquefied state. Multi-Flow Condenser Modulator Condensing Portion Gaseous Refrigerant Liquid Refrigerant Super-Cooling Portion 182BE48 159 BODY ELECTRICAL – AIR CONDITIONING High Pressure NOTE: The point at which the air bubbles disappear in the refrigerant of the sub-cool cycle is lower than the proper amount of refrigerant with which the system must be filled. Therefore, if the system is recharged with refrigerant based on the point at which the air bubbles disappear, the amount of refrigerant would be insufficient. As a result, the cooling performance of the system will be affected. For the proper method of verifying the amount of the refrigerant and to recharge the system with refrigerant, see the 2001 Prius Repair Manual (Pub. No.RM778U). Properly Recharged Amount Point in which Bubbles Disappear Amount of Refrigerant 152BE40 160 BODY ELECTRICAL – AIR CONDITIONING 3. Compressor General A compact and high performance scroll compressor with oil separator has been adopted. Construction The scroll compressor with oil separator consists of a spirally wound fixed scroll and variable scroll that form a pair, and oil separator, and a magnetic clutch. The fixed scroll is integrated with the housing. Because the rotation of the shaft causes the variable scroll to revolve while maintaining the same posture, the volume of the space that is partitioned by both scrolls varies to perform the suction, compression, and the discharge of the refrigerant gas. A pin is attached behind the variable scroll to prevent the autorotation of the variable scroll, allowing it only to revolve. Locating the suction port directly above the scrolls enables direct suction, thus realizing improved suction efficiency. Containing a built-in oil separator, this compressor is able to separate the compressor oil that is intermixed with the refrigerant and circulates in the refrigeration cycle, thus realizing a reduction in the oil circulation rate. Shaft Suction Port Magnetic Clutch Intake Port Oil Separator Discharge Port Pins Variable Scroll Discharge Port Fixed Scroll Fixed Scroll 165BE21 165BE22 161 BODY ELECTRICAL – AIR CONDITIONING Operation 1) Suction As the capacity of the compression chamber, which is created between the variable scroll and the fixed scroll, increases in accordance with the revolution of the variable scroll, refrigerant gas is drawn in from the intake port. 2) Compression From the state at which the suction process has been completed, as the revolution of the variable scroll advances further, the capacity of the compression chamber decreases gradually. Consequently, the refrigerant gas that has been drawn in becomes compressed gradually and is sent to the center of the fixed scroll. The compression of the refrigerant gas is completed when the variable scroll completes approximately 2 revolutions. 3) Discharge When the compression of the refrigerant gas is completed and the refrigerant pressure becomes high, the refrigerant gas discharges through the discharge port located in the center of the fixed scroll by pushing the discharge valve. Suction Intake Port Discharge Port Variable Scroll Fixed Scroll Compression Discharge 165BE23 162 BODY ELECTRICAL – AIR CONDITIONING Oil Separator 1) General A CS (Centrifugal with Shutter) type oil separator has been adopted to reduce the circulation rate of the compressor oil that is intermixed with the refrigerant and circulates in the refrigeration cycle. This oil separator is provided with a cylindrical pipe in the separator case, enabling the refrigerant gas that has been discharged through the discharge gas inlet to be separated into refrigerant gas and oil through centrifugal force, and minimizing the outflow of the oil to the discharge service port. As a result, the oil circulation rate has been reduced and makes energy savings possible. Condenser and Modulator Scroll Compressor with Oil Separator Separator Refrigerant Gas + Compressor Oil Compressor Oil Expansion Valve Compressor Evaporator 165BE24 163 BODY ELECTRICAL – AIR CONDITIONING 2) Construction and Operation The refrigerant gas that is discharged from the discharge port flows by rotating around the cylindrical pipe in the oil separator. At this time, the centrifugal force that is created during the rotation separates the refrigerant gas and the compressor oil due to the difference in their specific gravity. The refrigerant gas with the lighter specific gravity passes through the inside of the pipe and travels from the discharge service port to the outside of the compressor. The compressor oil with the heavier specific gravity is discharged through the oil discharge hole in the shutter and is stored in the oil storage chamber. Then, the compressor oil is fed again into the compressor and circulates inside the compressor. Discharge Port Discharge Service Port Refrigerant Refrigerant and Compressor Oil Pipe Oil Discharge Hole Compressor Oil Shutter Oil Storage Chamber Discharge Valve 165BE25 165BE26 4. Water Pump (For Air Conditioning) An electrical water pump with a bypass valve that provides a stable heater performance even if the engine is stopped due to a function of the THS has been adopted. When the engine is running, this water pump ceases its operation and opens the bypass valve to minimize the flow resistance of the coolant that is pumped by the engine water pump. Flow of Coolant Bypass Valve Water Pump OFF (Engine ON) Flow of Coolant Bypass Valve Water Pump ON (Engine OFF) 182BE19 182BE20 164 BODY ELECTRICAL – AIR CONDITIONING 5. Clean Air Filter A clean air filter that excels in removing pollen and dust is standard equipment. This filter, which cleans the air in the cabin, is made of polyester. Thus, it can be disposed of easily as a combustible material, a feature that is provided in consideration of the environment. To facilitate the replacement of the filter, a one-touch clip is used in the filter cover which is unified with filter case. Thus, a construction that excels in serviceability has been realized. Clean Air Filter One Touch Clip Glove Compartment Door Stopper Pin Service Tip The replacement interval for the clean air filter is 30,000 km or 2 years. However, it varies with the use conditions (or environment). 182BE21 165 BODY ELECTRICAL – AIR CONDITIONING 6. Air Conditioning ECU General  An automatic control type air conditioning has been adopted. This system uses an air conditioning ECU to perform the calculation of the required outlet air temperature control, temperature control, blower control, air inlet control, air outlet control, and compressor control. The information that is necessary for effecting the controls are the signals from the room temperature sensor, evaporator temperature sensor, and solar sensor that are directly transmitted to the air conditioning ECU, and the signals from the ambient temperature sensor and the engine coolant temperature sensor that are transmitted via the ECM. These signals are calculated by the air conditioning ECU to effect the proper control.
System Diagram  Air Conditioning ECU Room Temperature Sensor Evaporator Temperature Sensor BEAN Solar Sensor ECM Ambient Temperature Sensor Engien Coolant Temperature Sensor 182BE22 Sensors 1) Ambient Temperature Sensor The ambient temperature sensor has been provided on the left, in front of the condenser. The signals from this sensor are transmitted to the air conditioning ECU via the ECM. Ambient Temperature Sensor 182BE23 166 BODY ELECTRICAL – AIR CONDITIONING 2) Room Temperature Sensor The room temperature sensor has been provided inside the instrument finish lower panel. The signals from this sensor are directly transmitted to the air conditioning ECU. Room Temperature Sensor 182BE24 3) Evaporator Temperature Sensor The evaporator temperature sensor has been provided behind the evaporator in the air conditioning unit. The signals from this sensor are directly transmitted to the air conditioning ECU. Evaporator Temperature Sensor 182BE25 4) Solar Sensor The solar sensor has been provided on top of the instrument panel. The signals from this sensor are directly transmitted to the air conditioning ECU. Solar Sensor 182BE26 5) Engine Coolant Temperature Sensor The water temperature sensor has been provided on the water outlet area on the left side of the engine. The signals from this sensor are transmitted to the air conditioning ECU via the ECM. Engine Coolant Temperature Sensor 182BE27 BODY ELECTRICAL – AIR CONDITIONING 167 Calculation of Required Outlet Air Temperature (TAO: Temperature Air Outlet) After receiving the signals from the sensors and the temperature control switch setting, the air conditioning ECU uses the formula shown below to calculate the required outlet air temperature, to regulate the servomotors and blower motor. This is an outlet air temperature that is required in maintaining the set temperature in a stable manner. TAO = KSET x TSET – Kr x TR – KAM x TAMdisp – Ks x TS + C – TC KSET Kr KAM Ks C = Setting Temperature Coefficient = Room Air Temperature Coefficient = Ambient Air Temperature Coefficient p = Solar Radiation Coefficient = Correct Constant TSET TR TAMdisp p TS TC = Setting Temperature = Room Air Temperature = Ambient Air Temperature p = Solar Radiation = Compressor ON/OFF Correct = Constant Temperature Control System 1) Air Mix Damper Control In response to the temperature control switch setting, the required ambient temperature, evaporator temperature sensor, and engine coolant temperature sensor compensations are used by the air mix damper control to calculate a tentative damper opening angle, through an arithmetic circuit in the air mix damper, to arrive at a target damper opening angle.
Calculating the Target Damper Opening  Large Target Damper Opening Angle Small Small Large Tentative Damper Opening Angle 182BE50 168 BODY ELECTRICAL – AIR CONDITIONING Blower Control System 1) Blower Motor Startup Control When the blower motor is started up, the blower voltage in the auto mode (low speed) is output to the blower controller for 3 seconds. This is designed to protect the blower controller from a sudden startup current surge. 2) Manual Control Sets the blower speed according to operation of the blower switch. 3) Automatic Control a. Stepless Air Volume Control Ex-HI As shown on the right, when the AUTO switch on the heater control panel is pushed, the air conditioning ECU automatically reg- Blower Air ulates the voltage to the blower controller, in Volume accordance with the required outlet air temperature, to deliver stepless air volume. LO [C] Low Required Outlet Air Temperature High 174BE06 b. Warm-Up Control When the coolant temperature detected by the engine coolant temperature sensor is below a predetermined level and the air outlet is in the FOOT or BI-LEVEL mode, the blower does not operate. When the coolant temperature reaches specified temperature (b), the blower motor operates at low speed. When the coolant temperature is between specified temperature (b) to (c), the air flow calculation using the engine coolant temperature sensor signal, and, the air flow calculation using the required outlet air temperature are compared, and the lesser of the two is automatically selected as the air flow to be used. When the coolant temperature reaches specified temperature (c) or more, the blower motor runs at high speed. Moreover, when the coolant temperature is under specified temperature (a), and the warm-up control is effected (blower motor off), the air outlet is switched to the DEF mode. Later, when the blower motor turns on, the air outlet changes from the DEF mode to the FOOT or BI-LEVEL mode. HI Calculated Air Volume LO [C] OFF (a) (b) (c) Coolant Temperature 174BE07 169 BODY ELECTRICAL – AIR CONDITIONING c. Time-Lagged Air Flow Control 2 types of time-lagged air flow control (in accordance with the temperature detected by the evaporator temperature sensor) help prevent hot air from being emitted from FACE or BI-LEVEL vent. i) Evaporator temperature sensor at specified temperature or more As shown in the diagram on the right, this control turns OFF the blower motor for approximately specified time (a) and turns ON the compressor to cool the air conditioning unit. After approximately specified time (a) have elapsed, the blower motor rotates in the manual LO mode, allowing the cooled air to be discharged from the vents. Thus, the discomfort that is associated with the discharge of warm air is prevented. Between approximately specified time (b) to (c), the airflow volume according to the timelagged airflow control and the airflow volume of the blower control according to the calculation of the required outlet air temperature are compared. The airflow volume is then regulated at the smaller volume of the two. After specified time (c) have elapsed, control is effected by the blower control according to the calculation of the required outlet air temperature. Ex-HI Blower Air Volume LO 0 (a) (b) (c) Sec. Time 174BE08 ii) Evaporator temperature sensor at specified temperature or less As shown in the diagram on the right, for approximately specified time (a), the blower motor rotates in the manual LO mode. Thereafter, up to approximately specified time (b), the airflow volume according to the time-lagged airflow control and the airflow volume according to the blower control of the calculation of the required outlet air temperature are compared. The airflow volume is then regulated at the smaller volume of the two. After specified time (b) have elapsed, control is effected based on the blower control according to the calculation of the required outlet air temperature. Ex-HI Blower Air Volume LO 0 (a) (b) Time 174BE09 Sec. 170 BODY ELECTRICAL – AIR CONDITIONING d. Sunlight Air Flow Control Controls the blower speed in accordance with the intensity of the sunlight when the air outlet mode is at FACE or BI-LEVEL. The blower low speed can be adjusted up to 4 steps, in response to the sunlight signal received from the solar sensor. Hi Blower Air Volume Lo Small Large Amount of Sunligt 182BE51 2-Way Flow Mode Control At the time of selecting FRESH mode, air conditioning ECU will judge it as 2-way flow mode when the blower outlet is selected to FOOT or FOOT/DEF, the tentative air mix damper opening angle is above the specified valve (MAX HOT), and either the blower volume is more than the specified volume or the vehicle speed is less than the specified speed. 1 Fresh Air 0 Small Large Vehicle Speed Recirculation 182BE28 182BE29 Half Inlet Air Mode Control At the time of selecting FRESH mode, air conditioning ECU will judge it as half inlet air mode when the blower outlet mode is selected to FACE or BI-LEVEL and TAO (Temperature Air Outlet) is more than the specified temperature, and operates both outlet air introduction and inlet air circulation at the same time. Outlet Air Half Inlet Air Low High TAO (Temperature Air Outlet) 182BE52 171 BODY ELECTRICAL – AIR CONDITIONING Air Inlet Control System 1) Manual Control Drives the air inlet servomotor according to the operation of the air inlet control switch and fixes the dampers in the FRESH or RECIRC position. The 2-way flow mode control switches the recirculation/fresh-air function in accordance with the opening of the air mix damper, calculates the target opening of the damper, and rotates the servomotor. Damper Opening Recirculation / Fresh Air Switching Fresh Air 2-Way Flow MAX HOT Tentative Damper Opening Angle (During 2-Way Flow Mode) 182BE31 2) Battery ECU Forced Fresh Air Mode When the air conditioning ECU receives the forced fresh air mode signal from the battery ECU via the HV ECU and the ECM, the damper forcefully switches to the FRESH mode. 3) DEF, FOOT/DEF Mode Control When the mode switching switch is switched to FOOT/DEF mode from DEF mode or other than FOOT/DEF mode, air conditioning ECU switches to FRESH mode forcibly. Also, when the mode switching switch is switched to DEF mode from other than DEF mode, air conditioning ECU turns MAX mode ON and switched to FRESH mode forcibly. Compressor Control System 1) OFF Control Turns OFF the magnetic clutch of the compressor when the conditions for turning the blower motor OFF during warm-up control have been met. 2) Compressor Lock Judgment When the magnetic clutch is ON, if the air conditioning ECU judges that the compressor has been locked, it turns OFF the magnetic clutch relay and flashes the indicator lamp in the A/C or MAX switch. The conditions in which the ECU judges the compressor to have locked are when a slippage rate of 80% or more has been continued for 3 seconds or more. A/C Switch MAX Switch 182BE33 172 BODY ELECTRICAL – AIR CONDITIONING 3) Refrigerant Pressure Malfunction Detection By monitoring the pressure switch signal, this system can judge the refrigerant pressure to be abnormal, and turns off the compressor magnetic clutch relay, if the pressure switch remains off. 4) MAX Switch ON Control a. General In case of usual air conditioning operation, the air conditioning system shows superior control on cooling performance and fuel efficiency by combining the engine ON/OFF control by the hybrid control and the air conditioning ON/OFF control. In this MAX switch ON control, it controls by attaching greater importance to cooling performance of the air conditioning. BODY ELECTRICAL – ACCESSORIES 173 ACCESSORIES MULTI-INFORMATION DISPLAY 1. General  A multi-information display has been provided on top of the center console as standard equipment. Consisting of a 5.8-inch wide LCD (Liquid Crystal Display) screen, this multi-information display provides a vehicle information screen, warning screen, and an audio operation screen. The outside temperature is also shown on the screen.  A GPS (Global Positioning System) voice navigation is offered as an option. Through the use of the GPS and the map data in a DVD (Digital Versatile Disc), this navigation system analyzes the position of the vehicle and indicates that position on the map that is displayed on the screen. Additionally, it provides voice instructions to guide the driver through the route to reach the destination that has been selected. Listed below are the main functions of the multi-information display. Outline Function Map Screen Display*        Audio Screen Display Status of audio equipment and audio operation screen indication. Information Screen Display  Energy monitor screen indication.  Fuel consumption screen indication. Adjustment Screen Display  Sound quality adjustment screen indication.  Image quality adjustment screen indication.  No indication. On-screen Display  Audio status indication.  Warning indication. Interrupt Screen Display Warning indication. Diagnosis Screen Display  Display system diagnosis.  Displays various type of coefficient settings. Enlargement/reduction, rotation and movement of map. Indication of current position and direction of travel. Correction of current position. Setting, change and indication of route. Voice guidance. Indication of enlarged intersections. Memory and indication of map position. *: with GPS Voice Navigation System 174 BODY ELECTRICAL – ACCESSORIES 2. System Diagram Front LH Speaker (Voice Guidance) GPS Antenna BEAN Navigation ECU AVC-LAN Center Cluster Switches  Navigation-related  switches  Audio-related  switches Display ECU Gateway ECU Meter ECU ECM Audio Unit Multi-information Display 182BE34 3. Layout of Components Multi-information Display GPS Antenna* Navigation ECU* DVD* Center Cluster Switches and Audio Unit *: with GPS Voice Navigation System 182BE35 BODY ELECTRICAL – ACCESSORIES 175 4. Construction and Operation General This system mainly consists of a multi-information display, navigation ECU, display ECU, gateway ECU, GPS antenna and audio unit. The navigation ECU, display ECU, gateway ECU, and the audio unit all maintain communication through the AVC-LAN. Navigation ECU The navigation ECU is provided on the models with the GPS voice navigation. Based on the map data on the DVD, signals from the GPS satellites, signals from the built-in gyro sensor, and signals from the vehicle’s speed sensor, this ECU calculates the vehicle’s present position, direction of travel, and driven distance, and transmits the data to the display ECU. In addition, it outputs navigation voice instructions. Display ECU Upon receiving the vehicle information that is transmitted by the gateway ECU, the navigation information that is transmitted by the navigation ECU, and the operation information from the audio unit, the display ECU displays these data on the multi-information display. Gateway ECU The gateway ECU transmits the vehicle information to the display ECU in order for it to be displayed on multi-information display. Because vehicle information is transmitted by the ECUs that maintain communication on the BEAN (Body Electronics Area Network), the gateway ECU converts this information into signals for AVC-LAN use and sends it to the display ECU. GPS Antenna The GPS antenna is provided on the models with the GPS voice navigation. The GPS antenna receives signals from the GPS satellites that are located on the orbits that circle the earth at an approximate altitude of 20,000 km. The GPS satellites continuously transmit orbit signals and the signal transmission time. Multi-information Display  The multi-information display has the functions for displaying the map screen, audio screen, information screen, adjustment screen, interrupt screen, and on-screen.  This system’s self-diagnosis function can be displayed and operated on the multi-information display. For details, refer to the 2001 Prius Repair Manual (Pub. No. RM778U). 176 BODY ELECTRICAL – ACCESSORIES 1) Map Screen The map screen is a function that is provided in the GPS voice navigation system. Based on the map data on the DVD, signals from the GPS satellites, signals from the built-in gyro sensor, and signals from the vehicle’s speed sensor, the vehicle’s present position, direction of travel, and driven distance are calculated and displayed on this screen. This screen has the display functions listed below. Item Heading Up/North Up Changes the orientation of the map. Front Wide Displays a map in the direction of travel of the vehicle in an enlarged form. Stepless Scale Display Changes the scale of the map from the basic 11 steps to an even finer display. Direct Scale Change Directly select and display the map scale. Multi-step Scale Display Change and display the map scale in 11 stages. Map Display Scroll Display Destination Search Search Outline Scrolls the screen to display the desired point on the map. Split-view Display Displays different modes on a screen that is split into two views. Points-of-Interest Display Displays selected types of marks on the map. Taillight-interlocked Map Color Change Changes the displayed color on the map screen when the taillights are turned ON. Road Number Sign Board Display Displays the road numbers on the map. Hybrid Points-of-interest Search Narrows the search by names of the points-of-interest, category, and areas. Points-of-interest Pinpoint Display Pinpoints and displays the position of the point-ofinterest. House Number Search Searches for a house number. Special Memory Point Sets a pre-registered point as a destination point while driving. Nearest Points-ofInterest Search List Display Searches nearest points-of-interest and displays a list. Intersection Search By specifying two streets, the point at which they intersect is set as the destination point. Emergency Search Performs a specific search for hospitals, police stations, and dealers. Freeway Entrance/Exit Search Searches for the destination by the name of the street that connects to a freeway entrance/exit. Route Search Searches for multiple routes. Search Condition Designation Searches for the recommended, shortest, and other routes. Regulated Road Consideration Performs search while considering regulated roads. Avoidance Area Avoids a designated area and searches a route. (Continued) 177 BODY ELECTRICAL – ACCESSORIES Item Guidance Outline Right or Left Turn Guidance Voice guidance to instruct the direction of travel to be taken. Freeway Direction of Travel Guidance Voice guidance to instruct the direction of travel to take on the freeway. Distance Display to Destination Displays the distance from the present location to the destination. Freeway Branch Type Specimen Guidance Type specimen for guidance to a freeway branch. Intersection Zoom-in Display Zoom-in display when approaching an intersection. Turn List Display Displays a turn list on the right side of the two-screen display when approaching an intersection. 2) Information Screen The information screen provides two types of indications: the energy monitor screen indication that displays the present energy flow of the hybrid system, and the fuel consumption screen indication that displays the average fuel consumption rate, the amount of regenerative energy, and the instantaneous fuel consumption rate. a. Energy Monitor Screen Indication This screen indicates the energy transmission direction for checking the current drive method (engine, motor or both), the power generation status by the engine and status of regenerative energy use. 182BE36 b. Fuel Consumption Screen Indication This screen indicates the average fuel consumption, recovered energy and the current fuel consumption, all at once. The average fuel consumption is calculated using 5-minute units. The recovered energy over the past 5 minutes is indicated by symbols, with one mark representing 50 Wh. In addition, the total fuel consumption before resetting and the total travel distance are displayed at the right bottom of the screen. 182BE37 178 BODY ELECTRICAL – ACCESSORIES 3) Interrupt Screen a. General If an abnormal condition occurs in the vehicle system, even if another screen is being displayed, the interrupt screen automatically indicates a warning to inform the driver of an abnormality in the system. The warning indication screen flashes for 5 seconds the mark of the system in which the abnormality occurred. Then, it illuminates and remains displayed until the screen is switched or the system is reinstated to normal. EMPS System Abnormality Warning HV Battery Warning
THS Abnormality Warning 182BE38 List of Warning Display Items  Warning Display Item Description of Warning EMPS System Abnormality Warning When an abnormality occurs in the EMPS (Electric Motor-assisted Power Steering) system. HV Battery Warning* When the HV battery voltage drops. THS Abnormality Warning When an abnormality occurs in the THS (TOYOTA Hybrid System). *: While “READY” light is lighting. b. HV Battery Warning When starting THS (when turning the IG key to START position) and if HV battery is displayed in this interrupt screen, it means that HV battery has abnormality. 4) On-screen If the screen switches to another screen while displaying a warning indication, the mark of the system in which the abnormality occurred is displayed at the top right area of the screen. The displayed mark disappears when the system is reinstated to normal. 182BE39 BODY ELECTRICAL – ACCESSORIES 179 5. GPS (Global Positioning System) Voice Navigation General  The GPS (Global Positioning System) function receives, via an GPS antenna, the signals that are transmitted from the GPS satellites located in space at an approximate altitude of 20,000 km, in order to determine the vehicle’s present position.  The GPS voice navigation function combines the radiowave navigation system that determines the present position through the GPS signals, and the self-contained navigation system that detects the driven distance and the direction of travel through the speed sensors and the gyro sensor that is contained in the navigation ECU. The GPS voice navigation function is a high-precision navigation system that indicates the vehicle position on the map display on the DVD and guides the route from the present position to the destination on a map and pictogram and through voice instructions. The multi-information display shows the data that has been calculated by the radiowave navigation system and the self-contained navigation system. Construction and Operation The GPS voice navigation function consists of the following components:  GPS Antenna  Speed Sensor  GPS Receiver (contained in the navigation ECU)  Gyro Sensor (contained in the navigation ECU)  Navigation ECU  Speaker For details on the basic operation of the GPS antenna and the navigation ECU, see page 175. 1) Speed Sensor The navigation ECU will receive the vehicle speed signal directly from the meter ECU. 2) GPS Receiver The GPS receiver demodulates the signals that are received by the GPS antenna from the satellites and outputs them to the navigation ECU. 180 BODY ELECTRICAL – ACCESSORIES 3) Gyro Sensor The gyro sensor is designed to detect the yaw rate of vertical axis turn of the vehicle and installed in the Navigation ECU. The gyro sensor has a turning-fork shape type piezoelectric ceramic piece inside. This piezoelectric ceramic piece deforms by charging voltage and generates voltage by deforming with force. The piezoelectric ceramic piece inside the gyro sensor is vibrated by the driving circuit and when the vehicle turns (when the detection portion turns to the axis direction), coriolis force is added to the detection portion. With this force, the detection portion is twisted. The voltage generated by this twisting is signal-processed inside the gyro sensor and outputted. Navigation ECU receives this signal and judges the yaw rate of the vehicle. Turning Axis Center Vibration Direciton Coriolis Force Detection Portion 182BE49 4) Speaker Outputs the sound signals that are transmitted from the power amplifier. Also outputs the navigation voice instructions via the front left speaker. 181 BODY ELECTRICAL – ACCESSORIES 5) Detecting the Vehicle Position The navigation ECU calculates the position based on the principle of a 3-point measurement. The GPS satellites are equipped with high-precision clocks. Thus, the satellites are able to transmit continuous orbit signals and radiowave transmission time signals. The navigation ECU also contains a clock, which can understand the radiowave time signals that are received from the satellites. As a result, the length of time that is taken by the radiowaves to arrive from the satellites to the antenna can be determined. Thus, the lengths of time that elapse for the radiowaves of the 4 satellites to reach the antenna are measured. Each of these lengths of time are multiplied by the luminous flux (the rate of transmission of luminous energy: approximately 300,000 km per second), the results of which are the distances from the satellites to the antenna. Because the positions of the GPS satellites are known by their signals, the receiving point (vehicle position) can be rendered as the point in which the 4 spheres (of which the centers are the respective satellites) converge. However, due to the differences that exist between the clocks of the satellite and the ECU, the 4 spheres do not converge at a single point. Therefore, the ECU uses another satellite to calculate the point at which the 4 spheres converge at a single point and corrects its internal clock. As a result, the ECU determines the vehicle position and adjusts its internal clock to the clocks of the satellites. GPS Sateilites Difference Difference Difference Difference 151LBE24 182 BODY ELECTRICAL – ACCESSORIES POWER WINDOW SYSTEM The power window system has the following features:  This system includes one-touch auto-up and down and key-off operation function. The one-touch auto up and down function automatically fully closes and opens the driver’s side window. The key-off operation function makes it possible to operate the power windows for approximately 45 seconds after the ignition key is turned to the ACC or LOCK position, if the front doors are not opened. Also, a jam protection function has been adopted to the closing operation of the driver’s window. If a foreign object becomes jammed in the window during one-touch auto-up or key-off operation of the driver’s window, this function automatically stops the power window and moves it downward.  This system controls the driver’s door through the power window master switch, and the front passenger and rear passenger doors through the body ECU. The power window master switch and the body ECU maintain communication through the UART (Universal Asynchronous Receiver Transmitter).
System Diagram  Power Window Master Switch Rear LH Passenger Switch UART Body ECU Front Passenger Switch Rear RH Passenger Switch 182BE40 183 BODY ELECTRICAL – ACCESSORIES DOOR LOCK CONTROL SYSTEM The door lock control system has the following features:  This system has a “key-linked lock and unlock”, “key-confine prevention” and “manual unlock prohibition” functions.  A 2-step unlock function is provided to unlock the driver’s door by turning the key cylinder first and to unlock passenger’s door by turning it the second time.  The control of this system is effected by the body ECU. The door lock control signal from the driver’s door is transmitted from the power window master switch to the body ECU through the UART (Universal Asynchronous Receiver Transmitter).  If you unlock using the ignition key from the conditions in which all the doors are locked, the dome light will be lighted.
System Diagram  Door Control Switch (Manual) R R P Body ECU D UART Power Window Master Switch Door Control Switch (Key-linked) 182BE41 WIRELESS DOOR LOCK REMOTE CONTROL SYSTEM The wireless door lock remote control system has the following features:  In this system, the wireless door control receiver performs the code identification process and the body ECU effects the door lock control. Serial data link is provided for communication between the wireless door control receiver and the body ECU.  A key-holder type transmitter has been adopted, and it contains the following three switches: the door lock switch, door unlock switch, and panic switch.  A rolling code system, in which the signal configuration changes each time when a signal is transmitted by the transmitter, has been adopted.  Panic alarm operation has been adopted.  The verification light function has been adopted. When the transmitter is used to lock or unlock the doors, this function flashes the taillights to inform that the operation has been completed. However, at the time of unlocking, the dome light will be lighted. Transmitter Key Unlock Warning Switch Door Courtesy Switch Serial Data Link Door Lock Motors Horn Relay Body ECU Headlight Relay Wireless Door Control Receiver Taillight Relay 169BE10 184 BODY ELECTRICAL – ACCESSORIES HV IMMOBILISER SYSTEM The HV immobiliser system has a theft-deterrent system to disable the THS (TOYOTA Hybrid System) from starting using the ignition key without the ID code pre-registered. This system adopts a transponder system which uses a transponder chip embedded in the grip of the ignition key. When the coil located around the ignition key cylinder receives the ID code signal transmitted by the transponder chip, the ECU determines whether or not the ID code matches the code registered.
System Diagram  Transponder Key Coil Spark Plug Transponder Chip Key Cylinder Ignition Key Transponder Key Amplifier Transponder Key ECU ECM HV ECU MG1 MG2 Injector 182BE42 185 BODY ELECTRICAL – ACCESSORIES THEFT DETERRENT SYSTEM 1. General  The theft deterrent system uses the door lock control system components and some other parts. When somebody attempts to forcibly enter the vehicle or open the engine hood or luggage compartment door without a key, or when the battery terminals are removed and reconnected, the theft deterrent system sounds the vehicle’s horn, security horn and flashes the headlights, taillights, hazard lights and interior light for about one minute to alert. At the same time, it locks all the doors.  The control of this system is effected by the body ECU.
Wiring Diagram  From Battery DKL DKUL LSWD From Battery Power Window Master Switch Headlight Relay Taillight Relay Horn Relay HRLY Ignition Key SW IG TRLY To Headlight To Taillight To Vehicles Horn HR LSWP From Battery LSR Interior Light KSW DCTY Interior Light Relay PCTY RCTY Courtesy Switches LCTY Body ECU HCTY Security Horn LUG PKL Wireless Door Control Receiver PKUL Door Lock Motors MPX IND R R P D ECM Security Indicator 182BE43 186 BODY ELECTRICAL – ACCESSORIES
List of Input/Output Signals  Terminal Name Terminal Name Outline DKL Driver’s door key lock signal LCTY DKUL Driver’s door key unlock signal Driver’s door lock position switch signal Ignition key switch status signal Front passenger door lock position switch signal Rear left door lock position switch signal Ignition key cylinder’s key presence/absence signal Driver’s door courtesy switch status signal Front passenger door courtesy switch status signal Rear right door courtesy switch status signal HCTY LSWD IG LSWP LSR KSW DCTY PCTY RCTY LUG PKL PKUL Outline Rear left door courtesy switch status signal Hood courtesy switch status signal Luggage compartment door courtesy switch status signal Front passenger door key lock signal Front passenger door key unlock signal HRLY Output signal to headlight relay TRLY Output signal to taillight relay HR Output signal to vehicle horn relay MPX Multiplex Communication (BEAN) IND Output signal to security indicator 2. Operation Non-Alert State Condition (3) Condition (1) Alert Preparation State Condition (5) Condition (2) Alert State Condition (6) Condition (4) Alarm State Condition (5) Non-Alert State: When the security function is inactive Without having the ignition key in the ignition key cylinder, if any one of the conditions listed below exists, the system transfers to the alert preparation state. Condition (1)  When the doors, engine hood, and luggage compartment door are all closed, the ignition key is used to lock all doors.  When the doors, engine hood, and luggage compartment door are all closed, the wireless door lock remote control system is used to lock all doors.  When all doors are locked, if any door, engine hood, or luggage compartment door is changed from “close” to “open”, and “close” again, all doors, engine hood, and luggage compartment door will be locked. Alert Preparation State: a delay time until the alert state The system transfers to the alert state if the condition (2) listed below is met, and to the non-alert state if one of the conditions (3) is met. BODY ELECTRICAL – ACCESSORIES 187 Condition (2)  When the doors, engine hood, and luggage compartment door are all closed and locked, and 30 seconds have elapsed. Condition (3)  When one of the doors, engine hood, or luggage compartment door is changed from “close” to “open”.  When one of the doors, engine hood, or luggage compartment door is changed from “lock” to “unlock”.  When the ignition key is inserted in the ignition key cylinder.  When a terminal is disconnected from the battery and re-connected. Alert State: a state in which attempted theft can be detected The system transfers to the alarm state if any one of the conditions (4) listed below is met, or to the non-alert state if any one of the conditions (5) is met. Condition (4)  Any door, engine hood, or luggage compartment door is opened.  The ignition key or the wireless door lock remote control system other than the transmitter is used for unlocking.  The luggage compartment door is opened with something other than the ignition key.  The engine hood is opened.  A terminal is disconnected from the battery and re-connected.  The wiring harness is directly connected as if to turn the ignition switch ON. Condition (5)  The ignition key is used to unlock the doors or the luggage compartment door.  The transmitter of the wireless door lock remote control system is used to unlock the doors.  The ignition key is inserted in the ignition key cylinder and turned until the ignition switch is ON. Alarm State: a state in which attempted theft can be detected  When an attempted theft is detected, the system sounds the vehicle’s horn and the security horn, flashes the headlights, taillights, and hazard lights, and illuminates the interior light to alert the people in the area. If any one of the doors is unlocked, and the ignition key is not inserted in the ignition key cylinder, the system forcefully locks the doors once.  The system transfers to the alert state if the condition (6) described below is met, or, when the system is in the alarm state, it transfers to the non-alert state if any one of the conditions (5) described above is met. At this time, the taillights are illuminated for 2 seconds to inform the driver that an attempted theft has been detected. Condition (6)  After approximately 60 seconds of the alarm time have elapsed. 188 BODY ELECTRICAL – ACCESSORIES SRS AIRBAG AND SRS SIDE AIRBAG  The SRS (Supplemental Restraint System) airbags are provided for the driver and front passenger. The SRS airbags have been designed to help reducing the shocks to the heads and chests of the driver and front passenger in the event of a frontal impact collision as supplements to the seat belts. This system is a 3-sensor type airbag system to detect the impact during a front collision using the airbag sensor assemblies and front airbag sensor, and to make the airbag system and seat belt pretensioner operate as well. Also, the function of the ECU to memorize the seat belt wearing condition while inflating the airbag is added.  The SRS side airbags are provided for the driver and front passenger as an option. The SRS side airbags have been designed to help reducing the impact energy that is transmitted to the driver and front passenger in the event of a side collision. The driver side and the front passenger side are each provided with one sensor.  A fuel cut control has been adopted to stop the fuel pump when the SRS airbag is deployed, thus helping reduce fuel leakage. Inflator and Bag for Driver Inflator and Bag for Front Passenger SRS Warning Light Front Airbag Sensor (RH) Side Airbag Assembly (RH) Front Airbag Sensor (LH) Seat Belt Pretensioner (RH) Side Airbag Assembly (LH) Side Airbag Sensor (LH) Seat Belt Pretensioner (LH) Airbag Sensor Assembly
Side Airbag Sensor (RH) 182BE44 System Diagram  Front Airbag Sensors  Inflator  (For Driver and Front Passenger)  Seat Belt Pretensioner  (LH and RH) Airbag Sensor Assembly Collision Inflator (For Right Side or Left Side) Impact Side Airbag Sensor Collision Impact 182BE45 189 BODY ELECTRICAL – ACCESSORIES CRUISE CONTROL SYSTEM 1. General The Prius has adopted a cruise control system that uses the hybrid system, and it is offered as an option. This system, which is controlled by the HV ECU that is integrated with the cruise control ECU, operates the vehicle through an optimal combination of the drive forces of the electric motor and the engine in accordance with the setting on the cruise control switch. HV ECU Cruise Control Switch Signal Brake Cancel Signal (Stoplight Switch) Accelerator Opening Angle Signal (Accelerator Pedal Position Sensor) Shift Position Signal (Sift Position Sensor) Cruise Control Area
Switch Input Value
Processing
Required Vehicle Speed
Calculation Indicator Light ECM Hybrid Control Area
Required Torque
Calculation
Drive Force Distribution
between Engine and
Electric Motor Inverter Brake ECU 182BE46 2. Construction The cruise control system mainly consists of an HV ECU, cruise control switches, indicator, stoplight switch, accelerator pedal position sensor, and the shift position sensor. The table below shows each of the functions. Item Function HV ECU Controls all the functions of the cruise control system in accordance with the signals from the sensors. Cruise Control Main Switch Cruise control system’s ON/OFF signal requirement. Cruise Control Switch A three-directional switch that provides the SET/COAST, RESUME/ ACCEL, and CANCEL functions. It requires the functions and settings in accordance with its operations. Indicator Light It is provided in the combination meter to display whether the system is ON or OFF. Stop Light Switch Detects that the driver has stepped on the brake pedal. Accelerator Pedal Position Sensor Detects the accelerator pedal opening angle. Shift Position Sensor Detects the shift position. 190 BODY ELECTRICAL – ACCESSORIES
SEAT BELT WARNING SYSTEM 1. General A seat belt warning system has been adopted. If the driver’s seat belt is not buckled, the warning light flashes and the buzzer sounds. If the front passenger seat belt is not buckled, it flashes the warning light. When the ignition switch is turned ON, this system determines whether or not the seat belt is buckled by the ON or OFF condition of the switch that is provided in the seat belt buckle. The occupant detection sensor provided in the seat cushion of the front passenger seat determines whether or not an occupant is seated in the front passenger seat. Seat Belt Warning Light (Driver) Warning Buzzer (Driver) Seat Belt Warning Light (Front Passenger Side) Combination Meter Occupant Detection Sensor Seat Belt Buckle Switch Seat Belt Buckle Switch Driver Side Front Passenger Side 182BE47 2. Occupant Detection Sensor The occupant detection sensor, which is enclosed in the seat cushion of the front passenger seat, is used to detect whether or not the front passenger seat is occupied. This sensor, which is shaped as illustrated below, consists of a construction in which two sheets of electrodes sandwich a spacer. When the occupant is seated, the electrode sheets come in contact with each other through the hole that is provided in the spacer portion, thus enabling the current to flow. Thus, the sensor detects whether or not an occupant is seated in the front passenger seat. Electrode Sheet Spacer Occupant Detection Sensor Electrode Sheet Sensor OFF 159BE18 Occupant Front Passenger Seat Upside View 182BE53 Sensor ON 159BE19 192 APPENDIX MAJOR TECHNICAL SPECIFICATIONS Area Item U.S.A. and Canada Body Type 4-Door Sedan Vehicle Grade — Model Code Overall Major Dimensions & Vehicle Weights Effective Head Room mm (in.) 4305 (169.5) ← Width mm (in.) 1695 (66.7) ← Height mm (in.) 1465 (57.6) ← mm (in.) 2550 (100.4) ← Front mm (in.) 1475 (58.1) ← Rear mm (in.) 1480 (58.3) ← Front mm (in.) 985 (38.8) ← Rear mm (in.) 942 (37.1) ← Front mm (in.) 1047 (41.2) ← Rear mm (in.) 899 (35.4) ← Front mm (in.) 1342 (52.8) ← Rear mm (in.) 1325 (52.2) ← Front mm (in.) 815 (32.1) ← Rear mm (in.) 940 (37.0) ← mm (in.) 125 (4.9) ← Angle of Approach degrees 14° ← Angle of Departure degrees 22° ← Front kg (lb) 770 (1700) ← Rear kg (lb) 485 (1065) ← Total kg (lb) 1255 (1765) ← Front kg (lb) 890 (1965) ← Rear kg (lb) 750 (1650) ← Total kg (lb) Effective Leg Room Shoulder Room Overhang Min. Running Ground Clearance Curb Weight Gross Vehicle Weight 1640 (3615) ← 45* (11.9, 9.9) ← m3 (cu.ft.) 0.39 (137.7) ← Max. Speed km/h (mph) 160 (99.4) ← Max. Cruising Speed km/h (mph) 160 (99.4) ← ← Fuel Tank Capacity
(US. gal., lmp.gal.) Performance Luggage Compartment Capacity Acceleration Max. Permissible p Speed 0 to 100 km/h sec. 12.7 0 to 400 m sec. 19.0 ← 1st Gear km/h (mph) — — 2nd Gear km/h (mph) — — 3rd Gear km/h (mph) — — 4th Gear km/h (mph) — — Wall to Wall m (ft.) 10.2 (33.5) ← Curb to Curb m (ft.) 9.4 (30.8) ← 1NZ-FXE ← 16-Valve, DOHC ← 75.0 × 84.7 (2.95 × 3.33) ← 1497 (91.4) ← Compression Ratio 13.0 ← Carburetor Type SFI ← 95 ← Min. Turning Radius (Outside Front) Engine Type Engine Valve Mechanism Bore × Stroke mm (in.) Displacement cm3 (cu.in.) Engine Electrical Research Octane No. RON Max. Output (EEC) kW/rpm (HP@rpm) 52/4500 (70@4500) ← Max. Torque (EEC) N·m/rpm (lb-ft@rpm) 111/4200 (82@4200) ← Battery Capacity (5HR) 12 – 28 ← Watts — — kW — — — — Voltage & Amp. Hr. Alternator Output Starter Output Clutch Type P111 ← In First — — In Second — — In Third — — In Fourth — — In Fifth — — In Reverse — — — — 3.905 ← Front Ventilated Disc ← Rear L.T. Drum ← L.T. Drum ← Hydraulic ← P-Valve ← Front MacPherson Strut ← Rear Torsion Bean ← Front STD ← Rear STD ← Rack and Pinion ← 16.4~18.3 ← Electric Motor ← Transaxle Type Transmission Gear Ratio Counter Gear Ratio Chassis NHW11L-AEEEBK Length Wheel Base Tread NHW11L-AEEEBA Differential Gear Ratio (Final) Brake Type Parking Brake Type Brake Booster Type and Size Proportioning Valve Type Suspension Type Stabilizer Bar Steering Gear Type Steering Gear Ratio (Overall) Power Steering Type *: EPA / CARB ORVR Test conditions in. 5 10 15 20 25 30 35 40 45 50 55 60 65 70 IN–1 INTRODUCTION – HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL IN00U–36 GENERAL INFORMATION 1. INDEX An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you in finding your way through the manual, the section title and major heading are given at the top of every page. 2. PRECAUTION At the beginning of each section, a PRECAUTION is given that pertains to all repair operations contained in that section. Read these precautions before starting any repair task. 3. TROUBLESHOOTING TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the cause. The fundamentals of how to proceed with troubleshooting are described on page IN–30. Be sure to read this before performing troubleshooting. 4. PREPARATION Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Special Service Materials) which should be prepared before beginning the operation and explains the purpose of each one. 5. REPAIR PROCEDURES Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example: Filler Cap Float Clevis Pin  Gasket Reservoir Boot  Grommet Slotted Spring Pin Clip 12 (120, 9) Clevis 15 (155, 11) Snap Ring Washer Lock Nut Push Rod Piston Cylinder N·m (kgf·cm, ft·lbf) : Specified torque  Non–reusable part N17080 2001 PRIUS (RM778U) Author: Date: 1 IN–2 INTRODUCTION – HOW TO USE THIS MANUAL The procedures are presented in a step–by–step format:
The illustration shows what to do and where to do it.
The task heading tells what to do.
The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example: Task heading : what to do 21. CHECK PISTON STROKE OF OVERDRIVE BRAKE (a) Place SST and a dial indicator onto the overdrive brake piston as shown in the illustration. SST 09350–30020 (09350–06120) Illustration: what to do and where Set part No. Detailed text : Component part No. how to do task (b) Measure the stroke applying and releasing the compressed air (392 785 kPa, 4 8 kgf/cm 2 or 57 114 psi) as shown in the illustration. Piston stroke: 1.40 0.0669 in.) 1.70 mm (0.0551 Specification This format provides the experienced technician with a FAST TRACK to the information needed. The upper case task heading can be read at a glance when necessary, and the text below it provides detailed information. Important specifications and warnings always stand out in bold type. 6. REFERENCES References have been kept to a minimum. However, when they are required you are given the page to refer to. 7. SPECIFICATIONS Specifications are presented in bold type throughout the text where needed. You never have to leave the procedure to look up your specifications. They are also found in Service Specifications section for quick reference. 8. CAUTIONS, NOTICES, HINTS:
CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people.
NOTICES are also presented in bold type, and indicate the possibility of damage to the components being repaired.
HINTS are separated from the text but do not appear in bold. They provide additional information to help you perform the repair efficiently. 9. SI UNIT The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of Unit), and alternately expressed in the metric system and in the English System. Example: Torque: 30 N·m (310 kgf·cm, 22 ft·lbf) 2001 PRIUS (RM778U) Author: Date: 2 IN–3 INTRODUCTION – IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION IN0HK–02 VEHICLE IDENTIFICATION AND ENGINE AND MOTOR SERIAL NUMBER 1. VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the vehicle identification number plate and the certification label, as shown in the illustration. A: Vehicle Identification Number Plate B: Certification Label A B B04759 Engine Serial Number Motor Serial Number 2. (a) (b) ENGINE AND MOTOR SERIAL NUMBER The engine serial number is stamped on the engine block, as shown in the illustration. The motor serial numbers is stamped, as shown in the illustration. B13824 2001 PRIUS (RM778U) Author: Date: 3 IN–4 INTRODUCTION – REPAIR INSTRUCTIONS REPAIR INSTRUCTIONS IN0CO–17 GENERAL INFORMATION FI1066 BASIC REPAIR HINT (a) Use fender, seat and floor covers to keep the vehicle clean and prevent damage. (b) During disassembly, keep parts in the appropriate order to facilitate reassembly. (c) Installation and removal of battery terminal: (1) Before performing electrical work, disconnect the negative (–) terminal cable from the battery. (2) If it is necessary to disconnect the battery for inspection or repair, first disconnect the negative (–) terminal cable. (3) When disconnecting the terminal cable, to prevent damage to battery terminal, loosen the cable nut and raise the cable straight up without twisting or prying it. (4) Clean the battery terminals and cable ends with a clean shop rag. Do not scrape them with a file or other abrasive objects. (5) Install the cable ends to the battery terminals after loosening the nut, and tighten the nut after installation. Do not use a hammer to tap the cable ends onto the terminals. (6) Be sure the cover for the positive (+) terminal is properly in place. (d) Check hose and wiring connectors to make sure that they are connected securely and correctly. (e) Non–reusable parts (1) Always replace cotter pins, gaskets, O–rings, oil seals, etc. with new ones. (2) Non–reusable parts are indicated in the component illustrations by the ”” symbol. (f) Seal Lock Adhesive Z11554 Precoated parts Precoated parts are bolts, nuts, etc. that are coated with a seal lock adhesive at the factory. (1) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive. (2) When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads. 2001 PRIUS (RM778U) Author: Date: 4 IN–5 INTRODUCTION – REPAIR INSTRUCTIONS (3) (g) (h) (i) Medium Current Fuse and High Current Fuse Equal Amperage Rating (j) Precoated parts are indicated in the component illustrations by the ”
” symbol. When necessary, use a sealer on gaskets to prevent leaks. Carefully observe all specifications for bolt tightening torques. Always use a torque wrench. Use of special service tools (SST) and special service materials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure. A list of SST and SSM can be found in Preparation section in this manual. When replacing fuses, be sure the new fuse has the correct amperage rating. DO NOT exceed the rating or use one with a lower rating. BE1367 Illustration Symbol Part Name Abbreviation FUSE FUSE MEDIUM CURRENT FUSE M–FUSE HIGH CURRENT FUSE H–FUSE FUSIBLE LINK FL CIRCUIT BREAKER CB V00076 2001 PRIUS (RM778U) Author: Date: 5 IN–6 INTRODUCTION (k) (l) CORRECT (3) (4) (5) IN0253 (6) WRONG CORRECT (7) (8) IN0252 REPAIR INSTRUCTIONS 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 IN–8).  Cancel the parking brake on the pedal place and shift the transmission in N position.  When jacking up the front wheels of the vehicle at first place stoppers behind the rear wheels.  When jacking up the rear wheels of the vehicle at first place stoppers before the front wheels.  When either the front or rear wheels only should be jacked up, set rigid racks and place stoppers in front and behind the other wheels on the ground.  After the vehicle is jacked up, be sure to support it on rigid racks . It is extremely dangerous to do any work on a vehicle raised on a jack alone, even for a small job that can be finished quickly. Observe the following precautions to avoid damage to the following parts: (1) Do not open the cover or case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) (2) WRONG – To disconnect vacuum hoses, pull off the end, not the middle of the hose. To pull apart electrical connectors, pull on the connector itself, not the wires. Be careful not to drop electrical components, such as sensors or relays. If they are dropped on a hard floor, they should be replaced and not reused. When steam cleaning an engine, protect the electronic components, air filter and emission–related components from water. Never use an impact wrench to remove or install temperature switches or temperature sensors. When checking continuity at the wire connector, insert the tester probe carefully to prevent terminals from bending. When using a vacuum gauge, never force the hose onto a connector that is too large. Use a step–down adapter for adjustment. Once the hose has been stretched, it may leak air. 2001 PRIUS (RM778U) Author: Date: 6 IN–7 INTRODUCTION (m) Example (n) IN0002 (o) – REPAIR INSTRUCTIONS Installation and removal of vacuum hose: (1) When disconnecting vacuum hoses, use tags to identify how they should be reconnected to. (2) After completing a job, double check that the vacuum hoses are properly connected. A label under the hood shows the proper layout. Bleeding of hydraulic brake booster system: When repairing the hydraulic brake booster or ABS, bleeding the air out of the hydraulic brake booster (See page BR–4). Unless otherwise stated, all resistance is measured at an ambient temperature of 20°C (68°F). Because the resistance may be outside specifications if measured at high temperatures immediately after the vehicle has been running, measurement should be made when the engine has cooled down. 2001 PRIUS (RM778U) Author: Date: 7 IN–8 INTRODUCTION – REPAIR INSTRUCTIONS IN0CP–15 VEHICLE LIFT AND SUPPORT LOCATIONS Front JACK POSITION Front Rear Front crossmember Body (Position shown in the illustration) CAUTION :
When jacking–up the front and rear, make sure the vehicle is not carrying any extra weight.
Do not position the jack at the center of the rear axle beam. PANTOGRAPH JACK POSITION SUPPORT POSITION Safety stand and swing arm type lift B04744 2001 PRIUS (RM778U) IN–9 INTRODUCTION – REPAIR INSTRUCTIONS PLATE TYPE LIFT L B Attachment A C HINT : Left and right set position Place the vehicle over the center of the lift. Front and rear set position
Align the cushion gum ends of the plate with the attachment lower ends (A, C).
Align the attachment upper end (B) with the front jack supporting point (L). Attachment dimensions 85 mm (3.35 in.) 70 mm (2.76 in.) 100 mm (3.94 in.) 200 mm (7.87 in.) B04755 2001 PRIUS (RM778U) IN–10 INTRODUCTION – FOR ALL OF VEHICLES FOR ALL OF VEHICLES IN0HO–01 PRECAUTION 1. (a) (b) (c) (d) B04757 PRECAUTIONS FOR HIGH–VOLTAGE CIRCUIT INSPECTION AND SERVICE Engineers to be engaged in inspection and servicing related to high–voltage systems should undergo special training. All the high–voltage wire harness connectors are colored orange: the HV battery and other high–voltage components are identified by the ”High Voltage” caution labels. Do not carelessly touch these wires and components. Before inspecting or servicing the high–voltage system, be sure to take measures such as wearing insulated gloves and removing the service plug to prevent electrocution. Carry the removed service plug in your pocket to prevent other technicians from reinstalling it while you are servicing the vehicle. After removing the service plug, wait 5 minutes before touching any of the high–voltage connectors and terminals. HINT: The 5 minutes are required to discharge the high–voltage condenser inside the inverter. (e) (f) (g) B04746 Before wearing insulated gloves, make sure that they are not cracked, reptured, torn, or damaged in any other way. Do not wear wet insulated gloves. When servicing the vehicle, do not wear a metal object like a mechanical pencil or scale that may drop accidentally and cause a short circuit. Before touching a bare high–voltage terminal, wear insulated gloves and ensure that the terminal is not charged with electricity (approx. 0 V) using an electrical tester. 2001 PRIUS (RM778U) Author: Date: 10 IN–11 INTRODUCTION (h) (i) (j) B04747 (k) – FOR ALL OF VEHICLES After disconnecting or exposing a high–voltage connector or terminal, insulate it immediately using insulation tape. The screw of a high–voltage terminal should be tightened firmly to the specified torque. Both insufficient and excessive tightening torque can cause failure. Call other engineers’ attention to the vehicle which high– voltage system is being inspected or repaired by hanging a ”High Voltage Operation in Progress. Do Not Touch” sign (See the next page). After servicing the high–voltage system and before reinstalling 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 engaged. 2001 PRIUS (RM778U) Author: Date: 11 IN–12 INTRODUCTION – FOR ALL OF VEHICLES Person in charge: CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION. 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. B12120 2001 PRIUS (RM778U) Author: Date: 12 IN–13 INTRODUCTION – FOR ALL OF VEHICLES 2. PRECAUTIONS TO BE OBSERVED WHEN INSPECTING OR SERVICING ENGINE COMPARTMENT The PRIUS, automatically turns the engine ON and OFF when the ignition switch is set to the ON position provided that the READY light on the instrument panel is it. Before inspecting or servicing the engine compartment, therefore, remove the ignition switch key. B04748 3. ACTIONS TO BE TAKEN WHEN BATTERIES ARE DEPLETED Actions to be taken when the auxiliary battery is depleted (a) HINT: The following phenomena indicate that the auxiliary battery is depleted:
No display appears on the instrument panel when you turn the ignition switch to the ON position.
The hybrid system does not start.
The headlights are dark.
The sound from the horn is weak. NOTICE: Never use a quick charger. (1) Move the shift lever to the P position, and engage the parking brake. (2) Remove the ignition key plate from the ignition switch. (3) B04749 Using a booster cable, connect the 12 V battery of the rescue vehicle and auxiliary battery of the stalled vehicle, as shown in the illustration. Start the engine of the rescue vehicle and run the engine at a speed slightly higher than the idling speed for 5 minutes to charge the auxiliary battery of the stalled vehicle. Turn the ignition switch of the stalled vehicle to the START position to start the hybrid system. B04750 If the hybrid system fails to start and the master and HV battery warning lights come on, the HV battery may have been discharged. (6) Disconnect the booster cable in the reverse way of the connection procedure. NOTICE: If the auxiliary battery needs to be replaced, replace it only with a 12 V battery specially designed for the use of the PRIUS. 1. +Terminal 4. –Terminal 2. +Terminal (4) 3. –Terminal (5) 2001 PRIUS (RM778U) Author: Date: 13 IN–14 INTRODUCTION – FOR ALL OF VEHICLES (b) Actions to be taken when HV battery is depleted NOTICE: Leaving a vehicle alone for 2 – 3 months may cause electric discharge from HV battery. When this happens, replace the HV battery. B04762 4. INSPECTION MODE HINT:
The PRIUS automatically stops the engine while the vehicle is stopped with the engine warmed up and battery well charged if the A/C compressor operation is not required. Therefore, even if the vehicle stops for any reason such as a check of ignition timing, the inspection mode should be activated when continuous operation of the engine is required.
The PRIUS has a skid control as traction control function. When the wheel speed of the front wheels exceeds that of the rear wheels, this function restrains the wheel speed of the front wheels. It is necessary to activate the inspection mode and reset the skid control when turning only the front wheels using a speedometer tester. Activation inspection mode (Without using a hand–held tester) (1) Perform the following (2) through (6) within 60 sec. (2) Turn the ignition switch ON from OFF. (3) With the shift lever in P position, fully depress the accelerator pedal 2 times. (4) With the shift lever in N position, fully depress the accelerator pedal 2 times. (5) With the shift lever in P position, fully depress the accelerator pedal 2 times. (6) Activate the inspecting mode and check that the hybrid system error warning light on the multi–center display flashes. (7) Turning the ignition switch to START starts the engine’s continuous operation. NOTICE:
The idling speed in the inspection mode is approx. 1,000 rpm. The number of revolutions will increase up to 1,500 rpm if the accelerator pedal is depressed to a degree of less than 60%, and up to 2,250 rpm in a case of 60% or more.
If a diagnosis code is recorded when entering the inspection mode, the master warning light and the error warning light on the multi–center display is lit. 2001 PRIUS (RM778U) Author: Date: 14 IN–15 INTRODUCTION
– FOR ALL OF VEHICLES When the master warning light is lit during operation in the inspection mode, deactivate the inspection mode and inspect the diagnosed area. HINT: When continuous operation of the engine is required for such as an exhaust leakage inspection, it is advisable as an easier way to turn ON the FULL switch of the air conditioner. 5. (a) SPECIAL NOTES FOR VEHICLE INSPECTION Vehicle conditions (1) Before activating the service mode, turn the air conditioner off, start the engine with the shift lever at P position, and check that the engine stops within several seconds after starting. (Engine warm up check) (2) Activate the service mode and inspect the vehicle. The shift position for each test is as follows: Test item Shift lever position 1. Vehicle straight traveling test (side slip inspection) D 2. Braking force test N 3. Speedometer test D 4. Exhaust gas test (idling) P 5. Headlight test P (3) Reset the service mode immediately after completion of inspection. NOTICE: Traveling on a road without resetting the service mode may damage the transaxle. (b) Special notes for speedometer test NOTICE: Rapid starting or quick acceleration/deceleration based on the speedometer tester without load setting may damage the transaxle. (1) Depress the accelerator pedal slowly and gradually accelerate at the time of measurement. (2) After the measurement, use the brake to decelerate gradually and stop. (c) Special note for using the chassis dynamometer Always set an appropriate load before starting the test. NOTICE: Rapid starting or quick acceleration/deceleration with insufficient load may damage the transaxle. 2001 PRIUS (RM778U) Author: Date: 15 IN–16 INTRODUCTION 6. (a) (b) – FOR ALL OF VEHICLES ACTIONS TO BE TAKEN FOR VEHICLE DAMAGED BY IMPACT Items to be prepared (For operation at the site of accident)
Protective clothing (Insulated gloves, rubber gloves, goggles, and safety shoes)
Saturated boric acid solution 20 L (Procure 800 g of boric acid powder, put it into a container, and dissolve it in water.)
Red litmus paper
ABC fire extinguisher (Applicable to both oil flames and electrical flames)
Waste rags or old towels (For wiping off the electrolyte)
Vinyl tape (For insulating cable)
Electrical tester Actions to be taken at the place of accident (1) Wear insulated or rubber gloves, goggles and safety shoes. (2) Do not touch a bare cable that could be a high–voltage cable. If you need to touch it, or if you have a danger of making an accidental contact, wear insulated gloves, measure the voltage between the cable and body ground using an electrical tester, and insulate the cable using vinyl tape. (3) If the vehicle catches fire, use a ABC fire extinguisher to extinguish the fire. Trying to extinguish the fire using only a small amount of water can be more dangerous than effective: either use a greater amount of water from a fire hydrant or wait for the fire fighters. (4) If the vehicle is partially submerged in water, do not touch the service plug or any of the high–voltage components and cables because of the danger of electrocution. If you need to touch them, do so only after pulling the vehicle completely out of water. (5) Check the HV battery and nearby area for any leakage of the electrolyte. Do not touch any leaking liquid because it could be the highly alkaline electrolyte. If you need to wipe it off (using rags etc.), do so only after completing the following procedure: wear the rubber gloves and goggles, neutralize the electrolyte with saturated boric acid solution, and finally apply a red litmus paper to make sure that it does not turn blue. 2001 PRIUS (RM778U) Author: Date: 16 IN–17 INTRODUCTION – FOR ALL OF VEHICLES (6) If a damage to any of the high–voltage components and cables is suspected, cut the high–voltage circuit using the procedure below. High–voltage Part and Wiring HV Battery Inverter and Converter Power Cable Hybrid Transaxle B04751

Move the shift lever to the P position and engage the parking brake. Remove the ignition key. Then disconnect the cable from the negative (–) terminal of the auxiliary battery. 2001 PRIUS (RM778U) Author: Date: 17 IN–18 INTRODUCTION – FOR ALL OF VEHICLES
Remove the service plug with the insulated gloves on. B04757 If the service plug cannot be removed due to damage to the rear portion of the vehicle, remove the HV fuse or IGCT relay instead. (c) Moving the damaged vehicle HINT: If any of the following applies, tow the vehicle away using a tow truck lorry.
One or more of the high–voltage components and cables is damaged.
The driving, traction, or fuel system is damaged. Engine Room J/B HV Fuse Engine Room R/B No. 2 IGCT Relay B04752
B04760 The READY light is not lit when you turn ignition key to the ON position. NOTICE:
Before towing the vehicle away using a break down lorry, disconnect the cable from the negative (–) terminal of the auxiliary battery and remove the service plug. Only if none of the above applies and you see no problems that might affect the driving operation, you are allowed to drive the vehicle away from the place of accident.
Preform the procedure below if the READY light goes off or you detect an abnormal noise, abnormal smell, or strong vibration while traveling: (1) Park the vehicle in a safe place. (2) Move the shift lever to the P position and engage the parking brake. (3) Disconnect the cable from the negative (–) terminal of the auxiliary battery. (4) Remove the service plug with insulated gloves on. 2001 PRIUS (RM778U) Author: Date: 18 IN–19 INTRODUCTION – FOR ALL OF VEHICLES (d) Actions required after moving the damaged vehicle If you see any liquid on the road surface, it could be the leakage of the highly alkaline electrolyte. Wearing rubber gloves and goggles, apply a red litmus paper to the liquid. If the litmus paper turns blue, neutralize the liquid using the saturated boric acid solution and reapply a red litmus paper to make sure that it does not turn blue. Then wipe the liquid off from the road surface using waste rags, etc. (e) Items to be prepared (When repairing damaged vehicles)
Protective clothing (Insulated gloves, rubber gloves, goggles, and safety shoes)
Saturated boric acid solution 20 L (Procure 800 g of boric acid powder, put it into a container, and dissolve it in water.)
Red litmus paper
Waste rags or old towels (For wiping off the electrolyte)
Vinyl tape (For insulating cable)
Electrical tester (f) Precautions to be observed when servicing the damaged vehicle: (1) Wear insulated or rubber gloves, goggles, and safety shoes. (2) Do not touch a bare cable that could be a high–voltage cable. If you need to touch it, or if you have a danger of making an accidental contact, wear insulated gloves, measure the voltage between the cable and the body ground using an electrical tester, and insulate the cable using a vinyl tape. (3) Check the HV battery and nearby area for leakage. If you find any liquid, it could be the leakage of the highly alkaline electrolyte. Wear rubber gloves and goggles, and then apply a red litmus paper to the leak. If the litmus paper turns blue, neutralize the liquid using the saturated boric acid solution and reapply a red litmus paper to make sure that it does not turn blue. Then wipe the liquid off using waste rags etc. (4) If the electrolyte adheres to your skin, wash the skin immediately using the saturated boric acid solution or large amounts of water. If the electrolyte adheres to an article of clothing, take it off immediately. (5) If the electrolyte comes into contact with your eyes, call out loudly for help. Do not rub your eyes but wash them with the saturated boric acid solution or large amounts of water and seek medical care. 2001 PRIUS (RM778U) Author: Date: 19 IN–20 INTRODUCTION – FOR ALL OF VEHICLES (6) If a damage to any of the high–voltage components and cables is suspected, cut the high–voltage circuit using the procedure below:
Move the shift lever to the P position and engage the parking brake.
Remove the ignition key. Then disconnect the cable from the negative (–) terminal of the auxiliary battery.
Wear insulated gloves, and then remove the service plug.
If you cannot remove the service plug due to damage to the rear portion of the vehicle, remove the HV fuse or IGCT relay instead. (g) Precautions to be taken when disposing of the vehicle When scrapping the vehicle, remove the HV battery from the vehicle and return it through the route specified by the manufacturer. The same applies to any damaged HV battery. (h) Precautions to be observed when towing Tow the damaged vehicle with its front wheels or its front and rear wheels lifted off the ground. NOTICE: Towing the damaged vehicle with its front wheels on the ground may cause the motor to generate electricity. This electricity could, depending on the nature of the damage, leak and cause a fire. (i) Towing with 4 wheels on the ground NOTICE:
If you have to tow the damaged vehicle using a rope, do it at a speed below 30 km/h. Such towing operation is allowed only to cover very short distance, such as the distance to a tow truck lorry, for example.
Set the ignition switch to the ACC position and shift lever to the N position.
If you detect any abnormality in the damaged vehicle during the towing operation, stop the towing operation immediately. (j) Towing eyelet (1) Install the hook. (2) Hook a rope onto the illustrated point for towing. B04758 2001 PRIUS (RM778U) Author: Date: 20 IN–21 INTRODUCTION 7. (a) Negative Cable BO4111 (b) – FOR ALL OF VEHICLES FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER The PRIUS is equipped with an SRS (Supplemental Restraint System), such as the driver airbag, front passenger airbag assembly, side airbag assembly and seat belt pretensioner. Failure to carry out service operations in the correct sequence could cause the supplemental restraint system to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the supplemental restraint system, it is possible the SRS may fail to operate when required. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedure described in this manual. GENERAL NOTICE (1) Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diagnostic trouble codes become the most important source of information when troubleshooting. When troubleshooting the supplemental restraint system, always inspect the diagnostic trouble codes before disconnecting the battery (See page DI–497). (2) Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery. (The supplemental restraint system is equipped with a back–up power source so that if work is started within 90 seconds of disconnecting the negative (–) terminal cable from the battery, the SRS may deploy.) When the negative (–) terminal cable is disconnected from the battery, memory of the clock and audio systems will be cancelled. So before starting work, make a record of the contents memorized by the each memory system. Then when work is finished, reset the clock and audio systems as before. To avoid erasing the memory of each memory system, never use a back–up power supply from another battery. 2001 PRIUS (RM778U) Author: Date: 21 IN–22 INTRODUCTION – FOR ALL OF VEHICLES (3) Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, side airbag assembly and seat belt pretensioner should be inspected (See page RS–14, RS–28, RS–63 and BO–92). (4) Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. (5) Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. (6) Never disassemble and repair the airbag sensor assembly, steering wheel pad, front passenger airbag assembly, side airbag assembly or seat belt pretensioner. (7) If the airbag sensor assembly, steering wheel pad, front passenger airbag assembly, side airbag assembly or seat belt pretensioner has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones. (8) Do not directly expose the airbag sensor assembly, steering wheel pad, front passenger airbag assembly or seat belt pretensioner to hot air or flames. (9) Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting of the electrical circuit. (10) Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices. (11) After work on the supplemental restraint system is completed, check the SRS warning light (See page DI–497). (c) SPIRAL CABLE (in Combination Switch) The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, otherwise cable disconnection and other troubles may result. Refer to SR–14 of this manual concerning correct steering wheel installation. Marks F08459 2001 PRIUS (RM778U) Author: Date: 22 IN–23 INTRODUCTION (d) – FOR ALL OF VEHICLES STEERING WHEEL PAD (with Airbag) (1) When removing the steering wheel pad or handling a new steering wheel pad, it should be placed with the pad top surface facing up. Storing the pad with its metallic surface facing upward may lead to a serious accident if the airbag deploys for some reason. In addition do not store a steering wheel pad on top of another one. (2) Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous.) (3) Grease should not be applied to the steering wheel pad and the pad should not be cleaned with detergents of any kind. (4) Store the steering wheel pad where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise. (5) When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) under the steering column near the combination switch connector before starting work. (6) When disposing of a vehicle or the steering wheel pad alone, the airbag should be deployed using an SST before disposal (See page RS–16). Carry out the operation in a safe place away from electrical noise. Example: Correct Wrong B04764 Example: Z13950 2001 PRIUS (RM778U) Author: Date: 23 IN–24 INTRODUCTION (e) – FOR ALL OF VEHICLES FRONT PASSENGER AIRBAG ASSEMBLY (1) Always store a removed or new front passenger airbag assembly with the airbag deployment direction facing up. Storing the airbag assembly with the airbag deployment direction facing down could cause a serious accident if the airbag inflates. (2) Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous.) (3) Grease should not be applied to the front passenger airbag assembly and the airbag door should not be cleaned with detergents of any kind. (4) Store the airbag assembly where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise. (5) When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) installed on the assembly before starting work. (6) When disposing of a vehicle or the airbag assembly alone, the airbag should be deployed using an SST before disposal (See page RS–30). Perform the operation in a safe place away from electrical noise. Example: Correct Wrong B02420 Example: Z13951 2001 PRIUS (RM778U) Author: Date: 24 IN–25 INTRODUCTION (f) – FOR ALL OF VEHICLES SIDE AIRBAG ASSEMBLY (1) Always store a removed or new side airbag assembly with the airbag deployment direction facing up. Storing the airbag assembly with the airbag deployment direction facing down could cause a serious accident if the airbag deploys. (2) Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous.) (3) Grease should not be applied to the side airbag assembly and the surface should not be cleaned with detergents of any kind. (4) Store the airbag assembly where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise. (5) When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) under the seat before starting work. (6) When disposing of a vehicle or the side airbag assembly alone, the airbag should be deployed using an SST before disposal (See page RS–42). Perform the operation in a safe place away from electrical noise. Example: Correct Wrong B04766 Example: N21642 2001 PRIUS (RM778U) Author: Date: 25 IN–26 INTRODUCTION (g) – FOR ALL OF VEHICLES SEAT BELT PRETENSIONER (1) Never measure the resistance of the seat belt pretensioner. (This may cause the seat belt pretensioner to activate, which is very dangerous.) (2) Never disassemble the seat belt pretensioner. (3) Never install the seat belt pretensioner in another vehicle. (4) Store the seat belt pretensioner where the ambient temperature remains below 80°C (176°F) and away from electrical noise without high humidity. (5) When using electric welding, first disconnect the connector (yellow color and 2 pins) before starting work. (6) When disposing of a vehicle or the seat belt pretensioner alone, the seat belt pretensioner should be activated before disposal (See page BO–93). Perform the operation in a safe place away from electrical noise. (7) The seat belt pretensioner is hot after activation, so let it cool down sufficiently before the disposal. However never apply water to the seat belt pretensioner. Example: B02121 2001 PRIUS (RM778U) Author: Date: 26 IN–27 INTRODUCTION (h) (i) – FOR ALL OF VEHICLES AIRBAG SENSOR ASSEMBLY (1) Never reuse the airbag sensor assembly involved in a collision when the SRS has deployed. (2) The connectors to the airbag sensor assembly should be connected or disconnected with the sensor mounted on the floor. If the connectors are connected or disconnected while the airbag sensor assembly is not mounted to the floor, it could cause undesired ignition of the supplemental restraint system. (3) Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery, even if only loosing the set bolts of the airbag sensor assembly. WIRE HARNESS AND CONNECTOR The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are a standard yellow color. If the SRS wire harness becomes disconnected or the connector becomes broken due to an accident, etc., repair or replace it as shown on page RS–66. 2001 PRIUS (RM778U) Author: Date: 27 IN–28 INTRODUCTION – FOR ALL OF VEHICLES 8. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER CAUTION: If large amount of unburned gasoline flows into the converter, it may overheat and create a fire hazard. To prevent this, observe the following precautions and explain them to your customer. (a) Use only unleaded gasoline. (b) Avoid prolonged idling. Avoid running the engine at idle speed for more than 20 minutes. (c) Avoid spark jump test. (1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible. (2) While testing, never race the engine. (d) Avoid prolonged engine compression measurement. Engine compression tests must be done as rapidly as possible. (e) Do not run engine when fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter. (f) Avoid coasting with ignition turned off. (g) Do not dispose of used catalyst along with parts contaminated with gasoline or oil. 9. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM For vehicles with mobile communication systems such as two–way radios and cellular telephones, observe the following precautions. (1) Install the antenna as far as possible away from the ECU and sensors of the vehicle’s electronic system. (2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle’s electronic systems. For details about ECU and sensors locations, refer to the section on the applicable component. (3) Avoid winding the antenna feeder together with other wiring as much as possible, and also avoid running the antenna feeder parallel with other wire harnesses. (4) Check that the antenna and feeder are correctly adjusted. (5) Do not install powerful mobile communications system. 10. FOR USING OBD II SCAN TOOL OR TOYOTA HAND–HELD TESTER CAUTION: Observe the following items for safety reasons:
Before using the OBD II scan tool or TOYOTA hand–held tester, the OBD II scan tool’s instruction book or TOYOTA hand–held tester’s operator manual should be read thoroughly.
Be sure to route all cables securely when driving with the OBD II scan tool or TOYOTA hand– held tester connected to the vehicle. (i.e. Keep cables away from feet, pedals, steering wheel and shift lever.)
Two persons are required when test driving with the OBD II scan tool or TOYOTA hand–held tester, one person to drive the vehicle and the other person to operate the OBD II scan tool or TOYOTA hand–held tester. 2001 PRIUS (RM778U) Author: Date: 28 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–29 HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN05Y–22 GENERAL INFORMATION A large number of ECU controlled systems are used in the PRIUS. In general, the ECU controlled system is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshooting of these systems is not complex. If you have adequate understanding of the system and a basic knowledge of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the problem. This manual is designed through emphasis of the above standpoint to help service technicians perform accurate and effective troubleshooting, and is compiled for the following major ECU controlled systems: The troubleshooting procedure and how to make use of it are described on the following pages. System Page 6. Engine DI–1 7. Hybrid Vehicle Control System DI–174 8. HV Battery Control System DI–312 9. Anti–Lock Brake System With EBD & RBS DI–351 10.Electric Motor Power Steering DI–452 11.Supplemental Restraint System DI–495 12.Cruise Control System DI–640 13.Combination Meter System DI–662 14.Body Control System DI–678 15.Driver Door Control System DI–730 16.Multiplex Communication System DI–750 17.Navigation System DI–789 18.Air Conditioning System DI–864 FOR USING OBD II SCAN TOOL OR TOYOTA HAND–HELD TESTER
Before using the scan tool or tester, the scan tool’s instruction book or tester’s operator manual should be read thoroughly.
If the scan tool or tester cannot communicate with ECU controlled systems when you have connected the cable of the scan tool or tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. (1) If communication is normal when the tool is connected to another vehicle, inspect the diagnosis data link line (Bus
line) or ECU power circuit of the vehicle. (2) If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so perform the Self Test procedures outline in the Tester Operator’s Manual. 2001 PRIUS (RM778U) Author: Date: 29 IN–30 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN05W–24 HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure on the following page. Here, only the basic procedure is shown. Details are provided in Diagnostics section, showing the most effective methods for each circuit. Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that circuit. Vehicle Brought to Workshop 1 2 1 Ask the customer about the conditions and the environment when the problem occurred. Customer Problem Analysis Symptom Confirmation and Diagnostic Trouble Code Check 3 Symptom Simulation 2, 3 Confirm the symptoms and the problem conditions, and check the diagnostic trouble codes. (When the problem symptoms do not appear during confirmation, use the symptom simulation method described later on.) 4 Diagnostic Trouble Code Chart 5 6 Problem Symptoms Table Circuit Inspection or Parts Inspection 7 Repair 8 Confirmation Test End 2001 PRIUS (RM778U) 4, 5, 6 Check the results obtained in Step 2, then confirm the inspection procedure for the system or the part which should be checked using the diagnostic trouble code chart or the problem symptoms table. 7 Check and repair the affected system or part in accordance with the instructions in Step 6. 8 After completing repairs, confirm that the problem has been eliminated. (If the problem is not reproduced, perform the confirmation test under the same conditions and in the same environment as when it occurred for the first time.) INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–31 1. CUSTOMER PROBLEM ANALYSIS In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgment. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time it occurred. Important Point in the Problem Analysis: The following 5 items are important points in the problem analysis. Past problems which are thought to be unrelated and the repair history, etc. may also help in some cases, so as much information as possible should be gathered and its relationship with the problem symptoms should be correctly ascertained for reference in troubleshooting. A customer problem analysis table is provided in Diagnostics section for each system for your use. Important Points in the Customer Problem Analysis
What ––––– Vehicle model, system name
When ––––– Date, time, occurrence frequency
Where ––––– Road conditions
Under what conditions? ––––– Running conditions, driving conditions, weather conditions
How did it happen? ––––– Problem symptoms (Sample) Engine control system check sheet. CUSTOMER PROBLEM ANALYSIS CHECK ENGINE CONTROL SYSTEM Check Sheet Inspector’s Name Model and Model Year Driver’s Name Frame No. Data Vehicle Brought in Engine Model License No. Odometer Reading Problem Symptoms Customer’s Name Engine does not Start Engine does not crank Difficult to Start Engine cranks slowly Other Poor Idling Incorrect first idle Idling rpm is abnormal Rough idling Other Poor Drive ability Hesitation Knocking Engine Stall Soon after starting After accelerator pedal depressed After accelerator pedal released During A/C operation Shifting from N to D Other No initial combustion Back fire Other High ( Muffler explosion (after–fire) Others Data Problem Constant 2001 PRIUS (RM778U) Sometimes ( times per day/month) km miles No complete combustion rpm) Low ( Surging rpm) IN–32 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 2. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the PRIUS fulfills various functions. The first function is the Diagnostic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be output by the technician during troubleshooting. Another function is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly. By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can be performed effectively. Diagnostic functions are incorporated in the following systems in the PRIUS. Diagnostic Trouble Code Check Input Signal Check (Sensor Check) Diagnostic Test Mode (Active Test)  (with Check Mode)       (with Check Mode)   Anti–Lock Brake System With EBD & RBS    Electric Motor Power Steering  Supplemental Restraint System  Cruise Control System  Multiplex Communication System  Navigation System  Air Conditioning System  System Engine Hybrid Vehicle Control System HV Battery Control System 2001 PRIUS (RM778U)   INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–33 In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diagnostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition, it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes should be checked before and after the symptom confirmation to determine the current conditions, as shown in the table below. If this is not done, it may, depending on the case, result in unnecessary troubleshooting for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble code check. DIAGNOSTIC TROUBLE CODE CHECK PROCEDURE Diagnostic Trouble Code Check (Make a note of and then clear) Diagnostic Trouble Code Display Confirmation of Symptoms Diagnostic Trouble Code Check Problem symptoms Same diagnostic trouble code is exist displayed Normal code is displayed Normal Code Display 2001 PRIUS (RM778U) Problem Condition Problem is still occurring in the diagnostic circuit The problem is still occurring in a place other than in the diagnostic circuit (The diagnostic trouble code displayed first is either for a past problem or it is a secondary problem) No problem symptoms exist The problem occurred in the diagnostic circuit in the past Problem symptoms Normal code is exist displayed The problem is still occurring in a place other than in the diagnostic circuit No problem symptoms exist The problem occurred in a place other than in the diagnostic circuit in the past Normal code is displayed IN–34 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Taking into account the points on the previous page, a flow chart showing how to proceed with troubleshooting using the diagnostic trouble code check is shown below. This flow chart shows how to utilize the diagnostic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms table. Diagnostic trouble code check Making a note of and clearing of the diagnostic trouble codes displayed Symptom confirmation Problem symptoms exist No problem symptoms exist Simulation test using the symptom simulation methods Diagnostic trouble code check
Diagnostic trouble code displayed
Problem symptoms exist
Normal code displayed
Problem symptoms exist Troubleshooting of problem indicated by diagnostic trouble code Troubleshooting of each problem symptom 2001 PRIUS (RM778U)
Normal code displayed
No problem symptoms exist System Normal If a diagnostic trouble code was displayed in the initial diagnostic trouble code check, it indicates that the trouble may have occurred in a wire harness or connector in that circuit in the past. Therefore, check the wire harness and connectors (See page IN–41). INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–35 3. SYMPTOM SIMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer’s vehicle. No matter how much experience a technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem symptoms he will tend to overlook something important in the repair operation and make a wrong guess somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the engine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the problem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the external causes are applied to the vehicle in a stopped condition. Important Points in the Symptom Simulation Test: In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area or parts must also be found out. To do this, narrow down the possible problem circuits according to the symptoms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation test, judging whether the circuit being tested is defective or normal and also confirming the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes of the symptom. 1 VIBRATION METHOD: When vibration seems to be the major cause. CONNECTORS Slightly shake the connector vertically and horizontally. Shake Slightly WIRE HARNESS Slightly shake the wire harness vertically and horizontally. The connector joint, fulcrum of the vibration, and body through portion are the major areas to be checked thoroughly. Swing Slightly PARTS AND SENSOR Vibrate Slightly Apply slight vibration with a finger to the part of the sensor considered to be the problem cause and check that the malfunction occurs. HINT: Applying strong vibration to relays may result in open relays. V07268 2001 PRIUS (RM778U) IN–36 2 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HEAT METHOD: When the problem seems to occur when the suspect area is heated. Heat the component that is the likely cause of the malfunction with a hair dryer or similar object. Check to see if the malfunction occurs. M a l f u n ction NOTICE: (1) Do not heat to more than 60 °C (140 °F). (Temperature is limited not to damage the components.) (2) Do not apply heat directly to parts in the ECU. 3 WATER SPRINKLING METHOD: When the malfunction seems to occur on a rainy day or in a high–humidity condition. Sprinkle water onto the vehicle and check to see if the malfunction occurs. NOTICE: (1) Never sprinkle water directly into the engine compartment, but indirectly change the temperature and humidity by applying water spray onto the radiator front surface. (2) Never apply water directly onto the electronic components. HINT: If a vehicle is subject to water leakage, the leaked water may contaminate the ECU. When testing a vehicle with a water leakage problem, special caution must be taken. 4 OTHER: When a malfunction seems to occur when electrical load is excessive. Turn on all electrical loads including the heater blower, head lights, rear window defogger, etc. and check to see if the malfunction occurs. ON B02389 B02390 2001 PRIUS (RM778U) INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–37 4. DIAGNOSTIC TROUBLE CODE CHART The inspection procedure is shown in the table below. This table permits efficient and accurate troubleshooting using the diagnostic trouble codes displayed in the diagnostic trouble code check. Proceed with troubleshooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown below as an example.
DTC No. Indicates the diagnostic trouble code.
Page or Instructions Indicates the page where the inspection procedure for each circuit is to be found, or gives instructions for checking and repairs.
Trouble Area Indicates the suspect area of the problem.
Detection Item Indicates the system of the problem or contents of the problem. DTC CHART (SAE Controlled) HINT: Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument or other factors. If a malfunction code is displayed during the DTC check mode, check the circuit for that code listed in the table below. For details of each code, turn to the page referred to under the ”See page” for the respective ”DTC No.” in the DTC chart. DTC No. (See page) Detection Item Trouble Area P0100 (DI–24) Mass Air Flow Circuit Malfunction
Open or short in mass air flow meter circuit
Mass air flow meter
ECM P0101 (DI–28) Mass Air Flow Circuit Range/ Performance Problem
Mass air flow meter P0110 (DI–29) Intake Air Temp. Circuit Malfunction
Open or short in intake air temp. sensor circuit
Intake air temp. sensor
ECM P0115 (DI–33) Engine Coolant Temp. Circuit Malfunction
Open or short in engine coolant temp. sensor circuit
Engine coolant temp. sensor
ECM P0116 (DI–37) Engine Coolant Temp. Circuit Range/ Performance Problem
Engine coolant temp. sensor
Cooling system Throttle/ Pedal Position Sensor/Switch ”A” Circuit Malfunction
Open or short in throttle position sensor circuit
Throttle position sensor
ECM Throttle/ Pedal Position Sensor/ Switch ”A” Circuit Range / Performance Problem
Throttle position sensor 2001 PRIUS (RM778U) MIL* Memory IN–38 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 5. PROBLEM SYMPTOMS TABLE The suspected circuits or parts for each problem symptom are shown in the table below. Use this table to troubleshoot the problem when a ”Normal” code is displayed in the diagnostic trouble code check but the problem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts should be checked. HINT: When the problem is not detected by the diagnostic system even though the problem symptom is present, it is considered that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a system other than the diagnostic system.
Page Indicates the page where the flow chart for each circuit is located.
Circuit Inspection, Inspection Order Indicates the circuit which needs to be checked for each problem symptom. Check in the order indicated by the numbers.
Problem Symptom
Circuit or Part Name Indicates the circuit or part which needs to be checked. PROBLEM SYMPTOMS TABLE Symptom Suspect Area See page Engine does not crank (Does not start) 1. Starter and starter relay ST–2 ST–17 No initial combustion (Does not start) 1. ECM power source circuit 2. Fuel pump control circuit 3. Engine control module (ECM) DI–147 DI–151 IN–29 No complete combustion (Does not start) 1. Fuel pump control circuit DI–151 Engine cranks normally (Difficult to start) 1. Starter signal circuit 2. Fuel pump control circuit 3. Compression DI–144 DI–151 EM–3 Cold engine (Difficult to start) 1. Starter signal circuit 2. Fuel pump control circuit DI–144 DI–151 Hot engine 1. Starter signal circuit 2. Fuel pump control circuit DI–144 DI–151 High engine idle speed (Poor idling) 1. A/C signal circuit (Compressor circuit) 2. ECM power source circuit AC–88 idling) 1. A/C signal circuit 2. Fuel pump control circuit 1. Compression 2. Fuel pump control circuit 2001 PRIUS (RM778U) INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–39 6. CIRCUIT INSPECTION How to read and use each page is shown below.
Diagnostic Trouble Code No. and Detection Item
Circuit Description The major role and operation, etc. of the circuit and its component parts are explained. DTC P0325 Knock Sensor 1 Circuit Malfunction CIRCUIT DESCRIPTION Knock sensor is fitted to the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. DTC No. P0325 DTC Detecting Condition Trouble Area No knock sensor 1 signal to ECM with engine speed, 1,200 rpm or more.
Open or short in knock sensor1 circuit
Knock sensor 1 (looseness)
ECM If the ECM detects the above diagnosis conditions, it operates the fall safe function in which the corrective retard angle value is set to the maximum value.
Indicates the diagnostic trouble code, diagnostic trouble code set parameter and suspect area of the problem. WIRING DIAGRAM ECM Knock Sensor 1 GR 12 KNK E6 E1
Wiring Diagram This shows a wiring diagram of the circuit. Use this diagram together with ELECTRICAL WIRING DIAGRAM to thoroughly understand the circuit. Wire colors are indicated by an alphabetical code. B = Black, L = Blue, R = Red, BR = Brown, LG = Light Green, V = Violet, G = Green, O = Orange, W = White, GR = Gray, P = Pink, Y = Yellow, SB = Sky Blue The first letter indicates the basic wire color and the second letter indicates the color of the stripe. V08423 2001 PRIUS (RM778U) IN–40 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
Indicates the position of the ignition switch during the check. ON LOCK Ignition Switch ON Ignition Switch LOCK (OFF) START ACC Ignition Switch ACC Ignition Switch START
Inspection Procedure Use the inspection procedure to determine if the circuit is normal or abnormal, and, if it is abnormal, use it to determine whether the problem is located in the sensors, actuators, wire harness or ECU. INSPECTION PROCEDURE 1 Check continuity between terminal KNK of ECM connector and body ground. PREPARATION: (a) Remove the glove compartment (See page SF–68). (b) Disconnect the E6 connector of ECM. LOCK KNK CHECK: Measure resistance between terminal KNK of ECM connector and body ground. E6 Connector OK: Resistance: 1 MΩ or higher AB0117 A00265 A00255 OK Go to step 3. NG 2 Check knock sensor (See page SF–61). OK Replace knock sensor.
Indicates the place to check the voltage or resistance.
Indicates the connector position to checked, from the front or back side. Wire Harness Check from the connector back side. (with harness) Check from the connector front side. (without harness) In this case, care must be taken not to bend the terminals.
Indicates the condition of the connector of ECU during the check. KNK E6 Connector Connector being checked is connected. KNK E6 Connector Connector being checked is disconnected. V08425 2001 PRIUS (RM778U) INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–41 IN05X–14 HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE 1. FI0046 FI0047 FI0048 2001 PRIUS (RM778U) CONNECTOR CONNECTION AND TERMINAL INSPECTION
For troubleshooting, diagnostic trouble code charts or problem symptom table are provided for each circuit with detailed inspection procedures on the following pages.
When all the component parts, wire harnesses and connectors of each circuit except the ECU are found to be normal in troubleshooting, then it is determined that the problem is in the ECU. Accordingly, if diagnosis is performed without the problem symptoms occurring, refer to Step 8 to replace the ECU. So always confirm that the problem symptoms are occurring, or proceed with inspection while using the symptom simulation method.
The instructions ”Check wire harness and connector” and ”Check and replace ECU” which appear in the inspection procedure, are common and applicable to all diagnostic trouble codes. Follow the procedure outlined below whenever these instructions appear. OPEN CIRCUIT: This could be due to a disconnected wire harness, faulty contact in the connector, and a connector terminal pulled out, etc. HINT:
It is rarely the case that a wire is broken in the middle of it. Most cases occur at the connector. In particular, carefully check the connectors of sensors and actuators
Faulty contact could be due to rusting of the connector terminals, to foreign materials entering terminals or a deformation of connector terminals. Simply disconnecting and reconnecting the connectors once changes the condition of the connection and may result in a return to normal operation. Therefore, in troubleshooting, if no abnormality is found in the wire harness and connector check, but the problem disappears after the check, then the cause is considered to be in the wire harness or connectors. SHORT CIRCUIT: This could be due to a contact between wire harness and the body ground or to a short circuit occurred inside the switch, etc. HINT: When there is a short circuit between the wire harness and body ground, check thoroughly whether the wire harness is caught in the body or is clamped properly. IN–42 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 2. CONNECTOR HANDLING When inserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be accessed from behind, take good care not to deform the connector terminals. FI7187 Sensor Side ECU Side 3. (a) CONTINUITY CHECK (OPEN CIRCUIT CHECK) Disconnect the connectors at both ECU and sensor sides. (b) Measure the resistance between the applicable terminals of the connectors. Resistance: 1 Ω or less IN0379 ECU Side Sensor Side HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. IN0378 4. (a) (b) ECU Side Sensor Side IN0380 HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 5. (a) (b) Pull Lightly Looseness of Crimping IN0381 2001 PRIUS (RM778U) RESISTANCE CHECK (SHORT CIRCUIT CHECK) Disconnect the connectors on both ends. Measure the resistance between the applicable terminals of the connectors and body ground. Be sure to carry out this check on the connectors on both ends. Resistance: 1 MΩ or higher (c) VISUAL CHECK AND CONTACT PRESSURE CHECK Disconnect the connectors at both ends. Check for rust or foreign material, etc. in the terminals of the connectors. Check crimped portions for looseness or damage and check that the terminals are secured in lock portion. HINT: The terminals should not come out when pulled lightly from the back. INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–43 (d) Prepare a test male terminal and insert it in the female terminal, then pull it out. NOTICE: When testing a gold–plated female terminal, always use a gold–plated male terminal. HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section. Fig. 1 ECU Sensor C B 1 2 OPEN 1 1 2 2 A 1 2 6. CHECK OPEN CIRCUIT For the open circuit in the wire harness in Fig. 1, perform ”(a) Continuity Check” or ”(b) Voltage Check” to locate the section. Z17004 (a) Fig. 2 ECU C 1 2 Sensor B 1 2 A 1 2 Z17005 Fig. 3 ECU Sensor C 1 2 B2 1 2 B1 1 2 A 1 2 B04722 2001 PRIUS (RM778U) Check the continuity. (1) Disconnect connectors ”A” and ”C” and measure the resistance between them. In the case of Fig. 2: Between terminal 1 of connector ”A” and terminal 1 of connector ”C” → No continuity (open) Between terminal 2 of connector ”A” and terminal 2 of connector ”C” → Continuity Therefore, it is found out that there is an open circuit between terminal 1 of connector ”A” and terminal 1 of connector ”C”. (2) Disconnect connector ”B” and measure the resistance between the connectors. In the case of Fig. 3: Between terminal 1 of connector ”A” and terminal 1 of connector ”B1” → Continuity Between terminal 1 of connector ”B2” and terminal 1 of connector ”C” → No continuity (open) Therefore, it is found out that there is an open circuit between terminal 1 of connector ”B2” and terminal 1 of connector ”C”. IN–44 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS (b) Fig. 4 Sensor 5V A C 5V B 1 1 1 2 2 2 0V 5V Z17007 7. CHECK SHORT CIRCUIT If the wire harness is ground shorted as in Fig. 5, locate the section by conducting a ”continuity check with ground”. Fig. 5 C SHORT B 1 1 2 2 Check the voltage. In a circuit in which voltage is applied (to the ECU connector terminal), an open circuit can be checked for by conducting a voltage check. As shown in Fig. 4, with each connector still connected, measure the voltage between body ground and terminal 1 of connector ”A” at the ECU 5V output terminal, terminal 1 of connector ”B”, and terminal 1 of connector ”C”, in that order. If the results are: 5V: Between Terminal 1 of connector ”A” and Body Ground 5V: Between Terminal 1 of connector ”B” and Body Ground 0V: Between Terminal 1 of connector ”C” and Body Ground Then it is found out that there is an open circuit in the wire harness between terminal 1 of ”B” and terminal 1 of ”C”. A 1 2 Z17008 Fig. 6 ECU Sensor C 1 2 B 1 2 A 1 2 Z17009 2001 PRIUS (RM778U) Check the continuity with ground. (1) Disconnect connectors ”A” and ”C” and measure the resistance between terminal 1 and 2 of connector ”A” and body ground. In the case of Fig. 6: Between terminal 1 of connector ”A” and body ground → Continuity (short) Between terminal 2 of connector ”A” and body ground → No continuity Therefore, it is found out that there is a short circuit between terminal 1 of connector ”A” and terminal 1 of connector ”C”. INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–45 (2) Fig. 7 Sensor C 1 2 B2 1 2 B1 1 2 A 1 2 ECU Z17808 Disconnect connector ”B” and measure the resistance between terminal 1 of connector ”A” and body ground, and terminal 1 of connector ”B2” and body ground. In the case of Fig. 7: Between terminal 1 of connector ”A” and body ground → No continuity Between terminal 1 of connector ”B2” and body ground → Continuity (short) Therefore, it is found out that there is a short circuit between terminal 1 of connector ”B2” and terminal 1 of connector ”C”. 8. CHECK AND REPLACE ECU First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty, so replace the ECU with a normal functioning one and check that the symptoms appear. (1) Measure the resistance between the ECU ground terminal and the body ground. Resistance: 1 Ω or less Example Ground IN0383 (2) ECU Side Ground W/H Side Ground IN0384 2001 PRIUS (RM778U) Disconnect the ECU connector, check the ground terminals on the ECU side and the wire harness side for bend and check the contact pressure. IN–46 INTRODUCTION – TERMS TERMS IN04Q–11 ABBREVIATIONS USED IN THIS MANUAL Abbreviations Meaning ABS Anti–Lock Brake System AC Alternating Current ACC Accessory ACIS Acoustic Control Induction System ACSD Automatic Cold Start Device A.D.D. Automatic Disconnecting Differential A/F Air–Fuel Ratio AHC Active Height Control Suspension ALR Automatic Locking Retractor ALT Alternator AMP Amplifier ANT Antenna APPROX. Approximately A/T Automatic Transmission (Transaxle) ATF Automatic Transmission Fluid AUTO Automatic AUX Auxiliary AVG Average AVS Adaptive Variable Suspension BA Brake Assist BACS Boost Altitude Compensation System BAT Battery BDC Bottom Dead Center B/L Bi–Level B/S Bore–Stroke Ratio BTDC Before Top Dead Center BVSV Bimetallic Vacuum Switching Valve Calif. California CB Circuit Breaker CCo Catalytic Converter For Oxidation CD Compact Disc CF Cornering Force CG Center Of Gravity CH Channel COMB. Combination CPE Coupe CPS Combustion Pressure Sensor CPU Central Processing Unit CRS Child Restraint System CTR Center C/V Check Valve CV Control Valve 2001 PRIUS (RM778U) Author: Date: 46 IN–47 INTRODUCTION – TERMS CW Curb Weight DC Direct Current DEF Defogger DFL Deflector DIFF. Differential DIFF. LOCK Differential Lock D/INJ Direct Injection DLI Distributorless Ignition DOHC Double Over Head Cam DP Dash Pot DS Dead Soak DSP Digital Signal Processor EBD Electronic Brake Force Distribution ECAM Engine Control And Measurement System ECD Electronic Controlled Diesel ECDY Eddy Current Dynamometer ECU Electronic Control Unit ED Electro–Deposited Coating EDIC Electric Diesel Injection Control EDU Electronic Driving Unit EFI Electronic Fuel Injection E/G Engine EGR–VM Egr–Vacuum Modulator ELR Emergency Locking Retractor EMPS Electric Motor Power Steering ENG Engine ESA Electronic Spark Advance ETCS Electronic Throttle Control System EVP Evaporator E–VRV Electric Vacuum Regulating Valve EXH Exhaust FE Fuel Economy FF Front–Engine Front–Wheel–Drive F/G Fuel Gage FIPG Formed In Place Gasket FL Fusible Link F/P Fuel Pump FPU Fuel Pressure Up Fr Front FR Front–Engine Rear–Wheel–Drive F/W Flywheel FW/D Flywheel Damper FWD Front–Wheel–Drive GAS Gasoline GND Ground HAC 2001 PRIUS (RM778U) High Altitude Compensator Author: Date: 47 IN–48 INTRODUCTION – TERMS H/B Hatchback H–FUSE High Current Fuse HI High HID High Intensity Discharge (Head Lamp) HSG Housing HT Hard Top HV Hybrid Vehicle HWS Heated Windshield System IAC Idle Air Control IC Integrated circuit IDI Indirect Diesel Injection IFS Independent Front Suspension IG Ignition IIA Integrated Ignition Assembly IN Intake (Manifold, Valve) INT Intermittent I/P Instrument Panel IRS Independent Rear Suspension J/B Junction Block J/C Junction Connector KD Kick–Down LAN Local Area Network LB Liftback LCD Liquid Crystal Display LED Light Emitting Diode LH Left–Hand LHD Left–Hand Drive L/H/W Length, Height, Width LLC Long–Life Coolant LNG Liquified Natural Gas LO Low LPG Liquified Petroleum Gas LSD Limited Slip Differential LSP & PV Load Sensing Proportioning And Bypass Valve LSPV Load Sensing Proportioning Valve MAX. Maximum MG1 Motor Generator No. 1 MG2 Motor Generator No. 2 MIC Microphone MIL Malfunction Indicator Lamp MIN. Minimum MP Multipurpose MPX Multiplex Communication System M/T Manual Transmission MT Mount MTG 2001 PRIUS (RM778U) Mounting Author: Date: 48 IN–49 INTRODUCTION – TERMS N Neutral NA Natural Aspiration No. Number O/D Overdrive OEM Original Equipment Manufacturing OHC Overhead Camshaft OHV Overhead Valve OPT Option O/S Oversize P & BV Proportioning And Bypass Valve PCS Power Control System PCV Positive Crankcase Ventilation PKB Parking Brake PPS Progressive Power Steering PS Power Steering PTO Power Take–Off R&P Rack And Pinion R/B Relay Block RBS Recirculating Ball Type Steering R/F Reinforcement RFS Rigid Front Suspension RH Right–Hand RHD Right–Hand Drive RLY Relay ROM Read Only Memory Rr Rear RR Rear–Engine Rear–Wheel Drive RRS Rigid Rear Suspension RWD Rear–Wheel Drive SDN Sedan SEN Sensor SICS Starting Injection Control System SOC State Of Charge SOHC Single Overhead Camshaft SPEC Specification SPI Single Point Injection SRS Supplemental Restraint System SSM Special Service Materials SST Special Service Tools STD Standard STJ Cold–Start Fuel Injection SW Switch SYS System T/A Transaxle TACH Tachometer TBI 2001 PRIUS (RM778U) Throttle Body Electronic Fuel Injection Author: Date: 49 IN–50 INTRODUCTION – TERMS TC Turbocharger TCCS TOYOTA Computer–Controlled System TCV Timing Control Valve TDC Top Dead Center TEMP. Temperature TEMS TOYOTA Electronic Modulated Suspension TIS Total Information System For Vehicle Development T/M Transmission TMC TOYOTA Motor Corporation TMMK TOYOTA Motor Manufacturing Kentucky, Inc. TRAC Traction Control System TURBO Turbocharge U/D Underdrive U/S Undersize VCV Vacuum Control Valve VENT Ventilator VIN Vehicle Identification Number VPS Variable Power Steering VSC Vehicle Skid Control VSV Vacuum Switching Valve VTV Vacuum Transmitting Valve w/ With WGN Wagon W/H Wire Harness w/o Without 1st First 2nd Second 2WD Two Wheel Drive Vehicle (4x2) 4WD Four Wheel Drive Vehicle (4x4) 2001 PRIUS (RM778U) Author: Date: 50 IN–51 INTRODUCTION – TERMS IN0CI–02 GLOSSARY OF SAE AND TOYOTA TERMS This glossary lists all SAE–J1930 terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their TOYOTA equivalents. SAE ABBREVIATIONS TOYOTA TERMS ( )––ABBREVIATIONS SAE TERMS A/C Air Conditioning Air Conditioner ACL Air Cleaner Air Cleaner, A/CL AIR Secondary Air Injection Air Injection (AI) AP Accelerator Pedal B+ Battery Positive Voltage +B, Battery Voltage BARO Barometric Pressure HAC CAC Charge Air Cooler Intercooler CARB Carburetor Carburetor CFI Continuous Fuel Injection CKP Crankshaft Position Crank Angle CL Closed Loop Closed Loop CMP Camshaft Position Cam Angle CPP Clutch Pedal Position – CTOX Continuous Trap Oxidizer – CTP Closed Throttle Position LL ON, Idle ON DFI Direct Fuel Injection (Diesel) Direct Injection (DI) DI Distributor Ignition DLC1 DLC2 DLC3 Data Link Connector 1 Data Link Connector 2 Data Link Connector 3 1: Check Connector 2: Total Diagnosis Comunication Link (TDCL) 3: OBD II Diagnostic Connector DTC Diagnostic Trouble Code Diagnostic Code DTM Diagnostic Test Mode – ECL Engine Control Level – ECM Engine Control Module Engine ECU (Electronic Control Unit) ECT Engine Coolant Temperature Coolant Temperature, Water Temperature (THW) EEPROM Electrically Erasable Programmable Read Only Memory Electrically Erasable Programmable Read Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM) EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV) EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR) EI Electronic Ignition TOYOTA Distributorless Ignition (TDI) EM Engine Modification Engine Modification (EM) EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM) EVAP Evaporative Emission Evaporative Emission Control (EVAP) FC Fan Control – FEEPROM Flash Electrically Erasable Programmable Read Only Memory – FEPROM Flash Erasable Programmable Read Only Memory – FF Flexible Fuel – FP Fuel Pump Fuel Pump GEN Generator Alternator GND Ground Ground (GND) 2001 PRIUS (RM778U) – – – IN–52 INTRODUCTION – TERMS HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S) IAC Idle Air Control Idle Speed Control (ISC) IAT Intake Air Temperature Intake or Inlet Air Temperature ICM Ignition Control Module IFI Indirect Fuel Injection IFS Inertia Fuel–Shutoff – ISC Idle Speed Control – KS Knock Sensor Knock Sensor MAF Mass Air Flow Air Flow Meter MAP Manifold Absolute Pressure Manifold Pressure Intake Vacuum MC Mixture Control Electric Bleed Air Control Valve (EBCV) Mixture Control Valve (MCV) Electric Air Control Valve (EACV) MDP Manifold Differential Pressure MFI Multiport Fuel Injection Electronic Fuel Injection (EFI) MIL Malfunction Indicator Lamp Check Engine Lamp MST Manifold Surface Temperature – MVZ Manifold Vacuum Zone – NVRAM Non–Volatile Random Access Memory – O2S Oxygen Sensor Oxygen Sensor, O2 Sensor (O2S) OBD On–Board Diagnostic On–Board Diagnostic System (OBD) OC Oxidation Catalytic Converter Oxidation Catalyst Convert (OC), CCo OP Open Loop Open Loop PAIR Pulsed Secondary Air Injection Air Suction (AS) PCM Powertrain Control Module – PNP Park/Neutral Position – PROM Programmable Read Only Memory – PSP Power Steering Pressure – PTOX Periodic Trap Oxidizer Diesel Particulate Filter (DPF) Diesel Particulate Trap (DPT) RAM Random Access Memory Random Access Memory (RAM) RM Relay Module ROM Read Only Memory Read Only Memory (ROM) RPM Engine Speed Engine Speed SC Supercharger Supercharger SCB Supercharger Bypass E–ABV SFI Sequential Multiport Fuel Injection Electronic Fuel Injection (EFI), Sequential Injection SPL Smoke Puff Limiter – SRI Service Reminder Indicator – SRT System Readiness Test – ST Scan Tool – TB Throttle Body Throttle Body TBI Throttle Body Fuel Injection Single Point Injection Central Fuel Injection (Ci) TC Turbocharger Turbocharger TCC Torque Converter Clutch 2001 PRIUS (RM778U) – Indirect Injection (IDL) – – Torque Converter IN–53 INTRODUCTION – TERMS TCM Transmission Control Module Transmission ECU, ECT ECU TP Throttle Position Throttle Position TR Transmission Range TVV Thermal Vacuum Valve Bimetallic Vacuum Switching Valve (BVSV) Thermostatic Vacuum Switching Valve (TVSV) TWC Three–Way Catalytic Converter Three–Way Catalytic (TWC) Manifold Converter CCRO TWC+OC Three–Way + Oxidation Catalytic Converter CCR + CCo VAF Volume Air Flow Air Flow Meter VR Voltage Regulator Voltage Regulator VSS Vehicle Speed Sensor Vehicle Speed Sensor WOT Wide Open Throttle Full Throttle WU–OC Warm Up Oxidation Catalytic Converter – WU–TWC Warm Up Three–Way Catalytic Converter – 3GR Third Gear – 4GR Fourth Gear – 2001 PRIUS (RM778U) – MA–1 MAINTENANCE – OUTSIDE VEHICLE OUTSIDE VEHICLE MA02E–02 GENERAL MAINTENANCE These are maintenance and inspection items which are considered to be the owner’s responsibility. They can be done by the owner or they can have them done at a service shop. These items include those which should be checked on a daily basis, those which, in most cases, do not require (special) tools and those which are considered to be reasonable for the owner to do. Items and procedures for general maintenance are as follows. 1. GENERAL NOTES
Maintenance items may vary from country to country. Check the owner’s manual supplement in which the maintenance schedule is shown.
Every service item in the periodic maintenance schedule must be performed.
Periodic maintenance service must be performed according to whichever interval in the periodic maintenance schedule occurs first, the odometer reading (miles) or the time interval (months).
Maintenance service after the last period should be performed at the same interval as before unless otherwise noted.
Failure to do even one item an cause the engine to run poorly and increase exhaust emissions. 2. TIRES (a) Check the pressure with a gauge. If necessary, adjust. (b) Check for cuts, damage or excessive wear. 3. WHEEL NUTS When checking the tires, check the nuts for looseness or for missing nuts. If necessary, tighten them. 4. TIRE ROTATION Check the owner’s manual supplement in which the maintenance schedule is shown. 5. WINDSHIELD WIPER BLADES Check for wear or cracks whenever they do not wipe clean. If necessary, replace. 6. FLUID LEAKS Check underneath for leaking fuel, oil, water or other fluid. 7. DOORS AND ENGINE HOOD (a) Check that all doors including the trunk lid operate smoothly, and that all latches lock securely. (b) Check that the engine hood secondary latch secures the hood from opening when the primary latch is released. 2001 PRIUS (RM778U) Author: Date: 54 MA–2 MAINTENANCE – INSIDE VEHICLE INSIDE VEHICLE MA02F–02 GENERAL MAINTENANCE These are maintenance and inspection items which are considered to be the owner’s responsibility. They can be done by the owner or they can have them done at a service shop. These items include those which should be checked on a daily basis, those which, in most cases, do not require (special) tools and those which are considered to be reasonable for the owner to do. Items and procedures for general maintenance are as follows. 1. GENERAL NOTES
Maintenance items may vary from country to country. Check the owner’s manual supplement in which the maintenance schedule is shown.
Every service item in the periodic maintenance schedule must be performed.
Periodic maintenance service must be performed according to whichever interval in the periodic maintenance schedule occurs first, the odometer reading (miles) or the time interval (months).
Maintenance service after the last period should be performed at the same interval as before unless otherwise noted. 2. LIGHTS (a) Check that the headlights, stop lights, taillights, turn signal lights, and other lights are all working. (b) Check the headlight aim. 3. WARNING LIGHTS AND BUZZERS Check that all warning lights and buzzers function properly. 4. HORN Check that it is working. 5. WINDSHIELD GLASS Check for scratches, pits or abrasions. 6. WINDSHIELD WIPER AND WASHER (a) Check operation of the wipers and washer. (b) Check that the wipers do not streak. 7. WINDSHIELD DEFROSTER Check that air comes out from the defroster outlet when operating the heater or air conditioner. 8. REAR VIEW MIRROR Check that it is mounted securely. 9. SUN VISORS Check that they move freely and are mounted securely. 10. STEERING WHEEL Check that it has the specified freeplay. Be alert for changes in steering condition, such as hard steering, excessive freeplay or strange noises. 11. SEATS (a) Check that the seat adjusters operate smoothly. (b) Check that all latches lock securely in any position. (c) Check that the head restraints move up and down smoothly and that the locks hold securely in any latch position. (d) For fold–down seat backs, check that the latches lock securely. 12. SEAT BELTS (a) Check that the seat belt system such as the buckles, retractors and anchors operate properly and smoothly. (b) Check that the belt webbing is not cut, frayed, worn or damaged. 2001 PRIUS (RM778U) Author: Date: 55 MA–3 MAINTENANCE – INSIDE VEHICLE 13. ACCELERATOR PEDAL Check the pedal for smooth operation and uneven pedal effort or catching. 14. BRAKE PEDAL (See page BR–7) (a) Check the pedal for smooth operation. (b) Check that the pedal has the proper reserve distance and freeplay. 15. BRAKES At a safe place, check that the brakes do not pull to one side when applied. 16. PARKING BRAKE (See page BR–9) (a) Check that the pedal has the proper travel. (b) On a safe incline, check that the vehicle is held securely with only the parking brake applied. 17. TRANSAXLE ”PARK” MECHANISM (a) Check the lock release button of the selector lever for proper and smooth operation. (b) On a safe incline, check that the vehicle is held securely with the selector lever in ”P” position and all brakes released. 2001 PRIUS (RM778U) Author: Date: 56 MA–4 MAINTENANCE – UNDER HOOD UNDER HOOD MA02G–02 GENERAL MAINTENANCE 1. GENERAL NOTES
Maintenance items may vary from country to country. Check the owner’s manual supplement in which the maintenance schedule is shown.
Every serice item in the periodic maintenance schedule must be performed.
Periodic maintenance service must be performed according to whichever interval in the periodic maintenance schedule occurs first, the odometer reading (miles) or the time interval (months).
Maintenance service after the last period should be performed at the same interval as before unless otherwise noted. 2. WINDSHIELD WASHER FLUID Check that there is sufficient fluid in the tank. 3. ENGINE COOLANT LEVEL Check that the coolant level is between the ”FULL” and ”LOW” lines on the see–through reservoir. 4. RADIATOR AND HOSES (a) Check that the front of the radiator is clean and not blocked with leaves, dirt or bugs. (b) Check the hoses for cracks, kinks, rot or loose connections. 5. BRAKE FLUID LEVELS Check that the brake fluid levels are near the upper level line on the see–through reservoirs. 6. CHECK TRANSAXLE OIL (FLUID)
Visually check the transaxle for oil (fluid) leakage.
If leakage is found, check for the cause and repair. HINT: Wait until the engine and motor cools down (approx. 30 min.) before checking the fluid level after extended driving at high speeds, in hot weather, in heavy traffic or pulling a trailer. 2001 PRIUS (RM778U) Author: Date: 57 MA–5 MAINTENANCE – ENGINE ENGINE MA00R–17 INSPECTION HINT: Inspect these items when the engine is cold. 1. INSPECT DRIVE BELT (See page CO–4) 2. REPLACE SPARK PLUGS (See page IG–1) 3. (a) B08810 INSPECT AIR FILTER Visually check that the air filter is not excessively dirty or oily. HINT: Oiliness may indicate a stuck PCV valve. If necessary, replace the air cleaner element. (b) Clean the air filter with compressed air. First blow from the inside thoroughly, then blow off the outside of the element. 4. REPLACE AIR FILTER Replace the air filter with a new one. 5. REPLACE ENGINE OIL AND OIL FILTER (See page LU–3) 6. REPLACE ENGINE COOLANT (See page CO–2) 7. INSPECT CHARCOAL CANISTER (Se page EC–7) 8. REPLACE GASKET IN FUEL TANK CAP (See page SF–19) 9. INSPECT FUEL LINES AND CONNECTIONS (See page SF–19) 10. INSPECT EXHAUST PIPES AND MOUNTINGS (See page EC–13) 11. ADJUST VALVE CLEARANCE (See page EM–5) 2001 PRIUS (RM778U) Author: Date: 58 MA–6 MAINTENANCE – BRAKE BRAKE MA02H–03 INSPECTION S01304 1. INSPECT BRAKE LINE PIPES AND HOSES HINT: Check in a well lighted area. Check the entire circumference and length of the brake hoses using a mirror as required. Turn the front wheels fully right or left before checking the front brake. (a) Check all brake lines and hoses for:
Damage
Wear
Deformation
Cracks
Corrosion
Leaks
Bends
Twists (b) Check all clamps for tightness and connections for leakage. (c) Check that the hoses and lines are clear of sharp edges, moving parts and the exhaust system. (d) Check that the lines installed in grommets pass through the center of the grommets. 2. INSPECT FRONT BRAKE PADS AND DISCS (See page BR–29 ) HINT: If a squealing or scraping noise comes from the brake during, check the pad wear indicator to see if it is contacting the disc rotor. If so, the disc pad should be replaced. 3. INSPECT BRAKE LININGS AND DRUMS (See page BR–35) 2001 PRIUS (RM778U) Author: Date: 59 MA–7 MAINTENANCE – CHASSIS CHASSIS MA048–01 INSPECTION 1. (a) (b) INSPECT STEERING LINKAGE Check the steering wheel freeplay. (See page SR–3) Check the steering linkage for looseness or damage. Check that:
Tie rod ends do not have excessive play.
Dust seals and boots are not damaged.
Boot clamps are not loose. 2. INSPECT SRS AIRBAG (See page RS–2) 3. INSPECT STEERING GEAR HOUSING OIL Check the steering gear housing for oil leakage. 4. INSPECT DRIVE SHAFT BOOTS Check the drive shaft boots for clamp looseness, leakage or damage. 5. (a) Dust Cover S01303 INSPECT BALL JOINTS AND DUST COVERS Inspect the ball joints for excessive looseness.
Jack up the front of the vehicle and place wooden blocks with a height of 180 – 200 mm (7.09 – 7.87 in.) under the front tires.
Lower the jack until there is about half a load on the front coil spring. Place stands under the vehicle for safety.
Check that the front wheels are pointing straight ahead, and block them with chocks.
Using a lever, pry up the end of the lower arm, and check the amount of play. Maximum ball joint vertical play: 0 mm (0 in.) If there is play, replace the ball joint. (b) Check the dust cover for damage. 6. CHECK TRANSAXLE OIL (FLUID) Visually check the transaxle for oil (fluid) leakage. If leakage is found, check for the cause and repair. 7. REPLACE TRANSAXLE OIL (FLUID) Replace the transaxle oil (See page HT–26). 2001 PRIUS (RM778U) Author: Date: 60 MA–8 MAINTENANCE – BODY BODY MA049–01 INSPECTION 1. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY Tighten these parts:
Front seat mount bolts Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) P21235
Front suspension member–to–body mounting bolts Torque: Bolt A: 113 N·m (1,150 kgf·cm, 83 ft·lbf) Bolt B: 157 N·m (1,600 kgf·cm, 116 ft·lbf) F12933 2. (a) F12919 (b) (c)
Rear suspension member–to–body mounting nuts Torque: 90 N·m (918 kgf·cm, 66 ft·lbf) FINAL INSPECTION Check the operation of the body parts:
Hood: Auxiliary catch operate properly Hood locks securely when closed
Front and rear doors: Door lock operates properly Doors close properly
Luggage compartment door: Door lock operates properly
Seats: Seat adjusts easily and locks securely in any position Front seat back locks securely in any position Folding–down rear seat backs lock securely Road test:
Check the engine and chassis for abnormal noises.
Check that the vehicle does not wander or pull to one side.
Check that the brake work properly and do not drag. Be sure to deliver a clean car. especially check:
Steering wheel
Shift lever knob
All switch knobs
Door handles
Seats 2001 PRIUS (RM778U) Author: Date: 61 PP–1 PREPARATION – MAINTENANCE MAINTENANCE PP0E6–02 EQUIPMENT Mirror Brake hose Torque wrench 2001 PRIUS (RM778U) Author: Date: 62 PP–2 PREPARATION – ENGINE MECHANICAL ENGINE MECHANICAL PP3AW–01 SST (Special Service Tools) 09032–00100 Oil Pan Seal Cutter 09201–01055 Valve Guide Bushing Remover & Re placer 5.5 09201–41020 Valve Stem Oil Seal Replacer 09202–70020 Valve Spring Compressor (09202–00010) Attachment 09213–70010 Crankshaft Pulley Holding Tool 09221–25026 Piston Pin Remover & Replacer (09221–00021) Body (09221–00030) Spring (09221–00141) Guide H (09221–00150) Bushing ”D” (09221–00190) Guide ”K” 2001 PRIUS (RM778U) Author: Date: 63 PP–3 PREPARATION – ENGINE MECHANICAL 09222–30010 Connecting Rod Bushing Remover & Replacer 09223–15030 Oil Seal & Bearing Replacer 09330–00021 Companion Flange Holding Tool 09612–22011 Tilt Handle Bearing Replacer 09950–50012 Puller C Set (09951–05010) Hanger 150 (09952–05010) Slide Arm (09953–05020) Center Bolt 150 (09954–05020) Claw No.2 09950–70010 Handle Set (09951–07100) Handle 100 09301–00110 Clutch Guide Tool 2001 PRIUS (RM778U) Author: Date: 64 PP–4 PREPARATION – ENGINE MECHANICAL PP2FB–02 RECOMMENDED TOOLS 2001 PRIUS (RM778U) 09090–04020 Engine Sling Device 09200–00010 Engine Adjust Kit . 09258–00030 Hose Plug Set . PP–5 PREPARATION – ENGINE MECHANICAL PP2FC–02 EQUIPMENT Abrasive compound Valve Caliper gauge CO/HC meter Compression gauge Connecting rod aligner Cylinder gauge Dial indicator Dye penetrant Engine tune–up tester Groove cleaning tool Piston ring groove Heater Magnetic finger Micrometer Pin hole grinder Piston pin hole of piston Piston ring compressor Piston ring expander Plastigage Precision straight edge Press Ridge reamer Cylinder Soft brush Solvent Spring tester Valve spring Steel square Valve spring Thermometer Torque wrench Torx wrench socket set Stud bolt TOYOTA hand held tester or OBDII scan tool Valve seat cutter V–block Vernier calipers Wire brush 2001 PRIUS (RM778U) Valve PP–6 PREPARATION – ENGINE MECHANICAL PP2FD–02 SSM (Special Service Materials) 2001 PRIUS (RM778U) 08826–00080 Seal Packing Black or equivalent (FIPG) 08826–00100 Seal Packing 1282B, THREE BOND 1282B or equivalent (FIPG) 08833–00070 Adhesive 1324, THREE BOND 1324 or equivalent PP–7 PREPARATION – EMISSION CONTROL EMISSION CONTROL PP2FE–03 EQUIPMENT Torque wrench Vacuum gauge Pressure gauge Hose clipper MITYVAC (Hand–held vacuum pump) TOYOTA hand held tester or OBDII scan tool 2001 PRIUS (RM778U) Author: Date: 68 PP–8 PREPARATION – SFI SFI PP3AX–02 SST (Special Service Tools) 09268–21010 Fuel Hose Puller 09268–41047 Injection Measuring Tool Set (95336–08070) 09268–45014 Hose EFI Fuel Pressure Gauge (09268–41200) Gauge (09268–41220) Hose (09268–41250) T Joint 09816–30010 Oil Pressure Switch Socket 09842–30080 EFI Inspection Wire ”H” 09843–18020 Diagnosis Check Wire 2001 PRIUS (RM778U) Author: Date: 69 PP–9 PREPARATION – SFI PP2FQ–02 RECOMMENDED TOOLS 2001 PRIUS (RM778U) 09082–00040 TOYOTA Electrical Tester. 09200–00010 Engine Adjust Kit . 09258–00030 Hose Plug Set . Plug for the vacumm hose, fuel hose etc. PP–10 PREPARATION – SFI PP1WF–02 EQUIPMENT Carburetor cleaner Throttle body Graduated cylinder Injector TOYOTA hand held tester or OBD II scan tool Soft brush Throttle body Sound scope Injector Torque wrench Vacuum gauge 2001 PRIUS (RM778U) PP–11 PREPARATION – COOLING COOLING PP3AY–01 SST (Special Service Tools) 09960–10010 Variable Pin Wrench Set (09962–01000) Variable Pin Wrench Arm Assy (09963–00600) Pin 6 2001 PRIUS (RM778U) Author: Date: 72 PP–12 PREPARATION – COOLING PP2FG–02 RECOMMENDED TOOLS 09082–00040 2001 PRIUS (RM778U) TOYOTA Electrical Tester. PP–13 PREPARATION – COOLING PP2FH–02 EQUIPMENT Belt tension gauge Heater Thermostat Radiator cap tester Thermometer Torque wrench Vernier calipers 2001 PRIUS (RM778U) Thermostat PP–14 PREPARATION – COOLING PP2FI–03 COOLANT Item Engine coolant 2001 PRIUS (RM778U) Capacity 4.9 liters (5.2 US qts, 4.3 lmp. qts) Classification Ethylene–glycol base PP–15 PREPARATION – LUBRICATION LUBRICATION PP3AZ–01 SST (Special Service Tools) 09228–06501 Oil Filter Wrench 2001 PRIUS (RM778U) Author: Date: 76 PP–16 PREPARATION – LUBRICATION PP2FK–01 EQUIPMENT Oil pressure gauge Torque wrench Feeler gauge Straight edge 2001 PRIUS (RM778U) PP–17 PREPARATION – LUBRICATION PP2FL–03 LUBRICANT Item Engine oil Drain and refill w/ Oil filter change w/o Oil filter change Dry fill 2001 PRIUS (RM778U) Capacity Classification 3.7 liters (3.9 US qts, 3.3 lmp.qts) 3.4 liters (3.6 US qts, 3.0 lmp.qts) 4.1 liters (4.3 US qts, 3.6 lmp.qts) API grade SJ, Energy–Conserving or ILSAC multigrade engine oil. SAE 5W–30 is the best choice for your vehicle, for good fuel economy,and good starting in cold weather. PP–18 PREPARATION – LUBRICATION PP2FM–02 SSM (Special Service Materials) 08833–00080 2001 PRIUS (RM778U) Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent Oil pressure switch PP–19 PREPARATION – IGNITION IGNITION PP2FN–02 RECOMMENDED TOOLS 09082–00040 TOYOTA Electrical Tester. 09200–00010 Engine Adjust Kit . 2001 PRIUS (RM778U) Author: Date: 80 PP–20 PREPARATION – IGNITION PP2FO–01 EQUIPMENT Spark plug cleaner 2001 PRIUS (RM778U) PP–21 PREPARATION – HYBRID VEHICLE CONTROL HYBRID VEHICLE CONTROL PP3AS–01 RECOMMENDED TOOLS 09082–00040 TOYOTA Electrical Tester. 2001 PRIUS (RM778U) Author: Date: 82 PP–22 PREPARATION – HYBRID VEHICLE CONTROL PP3AT–01 EQUIPMENT Insulated gloves Insulated tools Vinyl tape Megger (500V) Megger (1000V) 2001 PRIUS (RM778U) PP–23 PREPARATION – HYBRID TRANSAXLE HYBRID TRANSAXLE PP3AM–01 SST (Special Service Tools) 09308–00010 Oil Seal Puller 09350–32014 TOYOTA Automatic Transmission Tool Set (09351–32130) Handle (09351–32150) Oil Seal Replacer 09388–40010 Input Oil Seal Replacer 09527–10011 Rear Axle Shaft Bearing Remover 09564–32011 Differential Preload Adaptor 09608–06041 Front Hub Inner Bearing Cone Replacer 09612–30012 Steering Worm Bearing Puller 09710–20011 Front Suspension Bushing Tool Set (09710–06071) 09710–22021 Replacer Front Suspension Bushing Tool Set 2001 PRIUS (RM778U) Author: Date: 84 PP–24 PREPARATION (09710–01031) – HYBRID TRANSAXLE Upper Arm Bushing Replacer 09950–00020 Bearing Remover 09950–40011 Puller B Set (09951–04010) Hanger 150 (09952–04010) Slide Arm (09953–04020) Center Bolt 150 (09954–04010) Arm 25 (09955–04061) Claw No.6 (09958–04011) Holder 09950–60010 Replacer Set (09951–00230) Replacer 23 (09951–00330) Replacer 33 (09951–00370) Replacer 37 2001 PRIUS (RM778U) Author: Date: 85 PP–25 PREPARATION (09951–00460) 09950–60020 – Replacer 46 Replacer Set No.2 (09951–00680) Replacer 68 09950–70010 Handle Set (09951–07100) Handle 100 09992–00095 HYBRID TRANSAXLE Automatic Transmission Oil Pressure Gauge Set (09992–00112) Adaptor A (09992–00271) Gauge Assy 2001 PRIUS (RM778U) Author: Date: 86 PP–26 PREPARATION – HYBRID TRANSAXLE PP3AN–01 RECOMMENDED TOOLS 2001 PRIUS (RM778U) 09025–00010 Torque Wrench (30 kgf–cm) 09031–00030 Pin Punch . 09040–00011 Hexagon Wrench Set . 09082–00040 TOYOTA Electrical Tester. 09090–04020 Engine Sling Device PP–27 PREPARATION – HYBRID TRANSAXLE PP3AO–01 EQUIPMENT Dial indicator Pin punch Straight edge Torque wrench 2001 PRIUS (RM778U) PP–28 PREPARATION – HYBRID TRANSAXLE PP3AP–01 LUBRICANT Item Hybrid transaxle oil 2001 PRIUS (RM778U) Capacity Classification 4.6 liters (4.9 US qts, 4.0 lmp. qts) ATF Type T–IV PP–29 PREPARATION – HYBRID TRANSAXLE PP3AQ–01 SSM (Special Service Materials) 2001 PRIUS (RM778U) 08826–00080 Seal Packing Black or equivalent (FIPG) 08826–00090 Seal Packing 1281, THREE BOND 1281 or equivalent (FIPG) 08833–00070 Adhesive 1324, THREE BOND 1324 or equivalent 08833–00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent PP–30 PREPARATION – SUSPENSION AND AXLE SUSPENSION AND AXLE PP3A9–01 SST (Special Service Tools) 09214–76011 Crankshaft Pulley Replacer Rear axle 09240–00020 Wire Gauge Set Front drive shaft 09520–00031 Rear Axle Shaft Puller (09520–00040) Shocker Front axle Rear axle (09521–00010) Attachment Front axle (09521–00020) Rod with Grip Front axle Rear axle 09520–01010 Drive Shaft Remover Attachment Front drive shaft 09520–24010 Differential Side Gear Shaft Puller Front drive shaft (09520–32040) Shocker Set 09521–24010 Drive Shaft Boot Clamping Tool Front drive shaft 09527–17011 Rear Axle Shaft Bearing Remover Front axle 09608–16042 Front Hub Bearing Adjusting Tool Front drive shaft 2001 PRIUS (RM778U) Author: Date: 91 PP–31 PREPARATION (09608–02021) Bolt & Nut (09608–02041) Retainer – SUSPENSION AND AXLE 09608–32010 Steering Knuckle Oil Seal Replacer Front axle 09628–10011 Ball Joint Puller Front axle Rear axle 09628–62011 Ball Joint Puller Front axle Front drive shaft Front suspension 09710–40010 Toe Control Link Replacer Arm Rear suspension (09711–40010) Toe Control Link Replacer Arm No.1 (09712–40010) Toe Control Link Replacer Arm No.2 09727–30021 Coil Spring Compressor (09727–00010) Bolt Set (09727–00021) Arm Set (09727–00031) Compressor 09729–22031 Front suspension Rear suspension Front Spring Upper Seat Holder Front suspension 2001 PRIUS (RM778U) Author: Date: 92 PP–32 PREPARATION – SUSPENSION AND AXLE 09751–36011 Brake Line Union Nut 10 x 12 mm Wrench Rear suspension 09930–00010 Drive Shaft Nut Chisel Front axle Front drive shaft 09950–00020 Bearing Remover Front drive shaft Rear axle 09950–40011 Puller B Set Front axle (09951–04020) Hanger 200 (09952–04010) Slide Arm (09953–04020) Center Bolt 150 (09954–04010) Arm 25 (09955–04011) Claw No.1 (09957–04010) Attachment (09958–04011) Holder 09950–60010 Replacer Set (09951–00370) Replacer 37 Front axle 2001 PRIUS (RM778U) Author: Date: 93 PP–33 PREPARATION – (09951–00550) Replacer 55 (09951–00650) Replacer 65 09950–60020 SUSPENSION AND AXLE Replacer Set No.2 (09951–00730) Replacer 73 09950–70010 Handle Set (09951–07150) Handle 150 Front axle Front axle 2001 PRIUS (RM778U) Author: Date: 94 PP–34 PREPARATION – SUSPENSION AND AXLE PP3A0–01 RECOMMENDED TOOLS 2001 PRIUS (RM778U) 09025–00010 Torque Wrench (30 kgf–cm) 09042–00010 Torx Socket T30 . 09905–00012 Snap Ring No.1 Expander . 09905–00013 Snap Ring Pliers . PP–35 PREPARATION – SUSPENSION AND AXLE PP0AM–01 EQUIPMENT Dial indicator with magnetic base Drill Torque wrench 2001 PRIUS (RM778U) PP–36 PREPARATION – SUSPENSION AND AXLE PP26B–05 LUBRICANT Item Capacity Front drive shaft Inboard joint grease Color=Yellow ocher 180 – 190 g (6.3 – 6.7 oz.) Color=Yellow ocher 110 – 120 g (3.9 – 4.2 oz.) Outboard joint grease 2001 PRIUS (RM778U) Application PP–37 PREPARATION – BRAKE BRAKE PP3BD–01 SST (Special Service Tools) 09023–00100 Union Nut Wrench 10 mm 09214–76011 Crankshaft Pulley Replacer 09318–12010 Transfer Bearing Adjusting Nut Wrench 09520–00031 Rear Axle Shaft Puller (09520–00040) Shocker (09521–00020) Rod with Grip 09950–00020 Bearing Remover 09703–30010 Brake Shoe Return Spring Tool 09709–29018 LSPV Gauge Set 09718–00010 Shoe Hold Down Spring Driver 09751–36011 Brake Line Union Nut 10 x 12 mm Wrench 09843–18040 Diagnosis Check Wire No.2 2001 PRIUS (RM778U) Author: Date: 98 PP–38 PREPARATION 09630–00014 (09631–00142) – BRAKE Power Steering Gear Housing Overhaul Tool Set Overhaul Stand 09950–60010 Replacer Set (09951–00180) Replacer 18 (09951–00190) Replacer 19 2001 PRIUS (RM778U) Author: Date: 99 PP–39 PREPARATION – BRAKE PP16D–04 RECOMMENDED TOOLS 2001 PRIUS (RM778U) 09082–00040 TOYOTA Electrical Tester. 09905–00013 Snap Ring Pliers . Master cylinder PP–40 PREPARATION – BRAKE PP16E–04 EQUIPMENT Torque wrench Micrometer Brake disc Dial indicator Brake disc Vernier calipers Brake disc Brake drum gauge Effort gauge 2001 PRIUS (RM778U) PP–41 PREPARATION – BRAKE PP16F–02 LUBRICANT Item Capacity Classification Brake fluid – SAE J1703 or FMVSS No. 116 DOT 3 2001 PRIUS (RM778U) PP–42 PREPARATION – STEERING STEERING PP3BA–01 SST (Special Service Tools) 09608–06041 Front Hub Inner Bearing Cone Replacer Tilt steering column 09612–00012 Rack & Pinion Steering Rack Housing Stand Electric motor power steering 09922–10010 Variable Open Wrench Electric motor power steering 09950–50012 Puller C Set Tilt steering column (09951–05010) Hanger 150 (09952–05010) Slide Arm (09953–05020) Center Bolt 150 (09954–05020) Claw No.2 2001 PRIUS (RM778U) Author: Date: 103 PP–43 PREPARATION – STEERING PP3BB–01 RECOMMENDED TOOLS 09042–00010 Torx Socket T30 . 09904–00010 Expander Set . (09904–00050) 2001 PRIUS (RM778U) No. 4 Claw 09905–00012 Snap Ring No.1 Expander . 09905–00013 Snap Ring Pliers . Tilt steering column PP–44 PREPARATION – STEERING PP0J9–10 EQUIPMENT Torque wrench 2001 PRIUS (RM778U) PP–45 PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM PP0SY–02 SST (Special Service Tools) 09082–00700 SRS Airbag Deployment Tool 09082–00750 Airbag Deployment Wire Sub–harness No.3 for Side Airbag Assembly 09082–00760 Airbag Deployment Wire Sub–harness No.4 for Driver’s and Front Passenger Airbag Assembly 09843–18040 Diagnosis Check Wire No.2 2001 PRIUS (RM778U) Author: Date: 106 PP–46 PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM PP2I6–01 RECOMMENDED TOOLS 09082–00040 2001 PRIUS (RM778U) TOYOTA Electrical Tester. PP–47 PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM PP0T0–01 EQUIPMENT Torque wrench Bolt: Length: 35 mm (1.38 in.) Pitch: 1.0 mm (0.039 in.) Diam: 6.0 mm (0.236 in.) Airbag disposal Tire Width: 185 mm (7.28 in.) Inner diam: 360 mm (14.17 in.) Airbag disposal Tire with disc wheel Width: 185 mm (7.28 in.) Inner diam: 360 mm (14.17 in.) Airbag disposal Vinyl bag Airbag disposal 2001 PRIUS (RM778U) PP–48 PREPARATION – BODY ELECTRICAL BODY ELECTRICAL PP26C–02 SST (Special Service Tools) 09843–18040 Diagnosis Check Wire No.2 2001 PRIUS (RM778U) Author: Date: 109 PP–49 PREPARATION – BODY ELECTRICAL PP26D–02 RECOMMENDED TOOLS 2001 PRIUS (RM778U) 09082–00040 TOYOTA Electrical Tester. 09041–00030 Torx Driver T30 . Steering wheel pad 09042–00010 Torx Socket T30 . Steering wheel pad PP–50 PREPARATION – BODY ELECTRICAL PP26E–02 EQUIPMENT Voltmeter Ammeter Ohmmeter Test lead Syphon Brake fluid level warning switch Bulb (3.4W) Fuel sender gauge, Fuel level warning switch Dry cell battery Wireless door lock transmitter Torque wrench Masking tape Rear window defogger wire Tin foil Rear window defogger wire 2001 PRIUS (RM778U) PP–51 PREPARATION – BODY ELECTRICAL PP26F–03 SSM (Special Service Materials) 08888–88888 2001 PRIUS (RM778U) DuPont Paste No. 4817 or equivalent Rear window defogger PP–52 PREPARATION – BODY BODY PP3B4–01 SST (Special Service Tools) 09812–00010 Door Hinge Set Bolt Wrench 09804–24010 Luggage Compartment Door Torsion Bar Tool 09082–00700 SRS Airbag Deployment Tool 09082–00730 Airbag Deployment Wire Sub–Harne ss No.1 09082–00740 Airbag Deployment Wire Sub–harness No.2 2001 PRIUS (RM778U) Author: Date: 113 PP–53 PREPARATION – BODY PP3B0–01 RECOMMENDED TOOLS 09050–20010 Air Riveter. (09050–02010) Dust Cap. (09050–02020) Nose Piece No.1. 09050–00032 2001 PRIUS (RM778U) Air Drill (09050–00210) Chuck Set (09050–00220) Handle 09060–60350 Revet Cutter. 09070–20010 Moulding Remover . PP–54 PREPARATION – BODY PP3B1–01 EQUIPMENT Clip remover Torque wrench Hexagon wrench (6 mm) Torx driver Hog ring pliers Hand riveter Tape To avoid surface damage Adhesive tape To avoid surface damage Double–stick tape Adhesive Cleaner Shop rag Knife Sealer gun Brush Putty spatula Glass plate or similar object Wooden block or similar object Heat light Piano wire Rope (no projections, difficult to break) Seat belt pretensioner Tire with disk wheel Width: 185 mm (7.28 in.) Inner diam: 360 mm (14.17 in.) Seat belt pretensioner Vinyl bag Seat belt pretensioner 2001 PRIUS (RM778U) PP–55 PREPARATION – BODY PP3B2–01 LUBRICANT Item MP grease 2001 PRIUS (RM778U) Capacity classification – – PP–56 PREPARATION – BODY PP3B3–01 SSM (Special Service Materials) 2001 PRIUS (RM778U) 08833–00070 Adhesive 1324, THREE BOND 1324 or equivalent 08833–00070 Adhesive 1324, THREE BOND 1324 or equivalent 08850–00801 Windshield Glass Adhesive Set or equivalent PP–57 PREPARATION – AIR CONDITIONING AIR CONDITIONING PP3AD–01 SST (Special Service Tools) 07110–58060 Air Conditioner Service Tool Set (07117–78050) Refrigerant Charging Gauge (07117–88060) Refrigerant Charging Hose Discharge (Red) (07117–88070) Refrigerant Charging Hose Suction (Blue) (07117–88080) Refrigerant Charging Hose Utility (Green) (07117–58060) Refrigerant Drain Service Valve (07117–58080) Quick Disconnect Adapter Discharge (diam. 16 mm) (07117–58090) Quick Disconnect Adapter Suction (diam. 13 mm) (07117–58070) T–Joint 07116–38360 Gas Leak Detector Assembly 07112–76050 Magnetic Clutch Stopper 07112–66040 Magnetic Clutch Remover 2001 PRIUS (RM778U) Author: Date: 118 PP–58 PREPARATION – AIR CONDITIONING 09870–00015 A/C Quick Joint Puller No.1 Suction tube 09870–00025 A/C Quick Joint Puller No.2 Liquid tube 2001 PRIUS (RM778U) Author: Date: 119 PP–59 PREPARATION – AIR CONDITIONING PP3AE–01 RECOMMENDED TOOLS 09040–00011 2001 PRIUS (RM778U) Hexagon Wrench Set . (09043–20050) Socket Hexagon Wrench 5. Expansion valve 5.0 mm (0.20 in.) (09043–20100) Socket Hexagon Wrench 10. Radiator & condenser module 10 mm (0.39 in.) 09082–00040 TOYOTA Electrical Tester. 09216–00021 Belt Tension Gauge . 09905–00013 Snap Ring Pliers . PP–60 PREPARATION – AIR CONDITIONING PP3AF–02 EQUIPMENT Voltmeter Ammeter Ohmmeter Test lead Thermometer Sensor, ECT switch Torque wrench Dial indicator Magnetic clutch Plastic hammer Magnetic clutch 2001 PRIUS (RM778U) PP–61 PREPARATION – AIR CONDITIONING PP3AG–01 LUBRICANT Item Compressor oil Capacity Classification – ND–OIL 8 or equivalent When replacing condenser 40 cc (1.4 fl.oz.) When replacing evaporator 40 cc (1.4 fl.oz.) When replacing compressor 120 cc (4.1 fl.oz.) 2001 PRIUS (RM778U) SS–1 SERVICE SPECIFICATIONS – STANDARD BOLT STANDARD BOLT SS0ZS–01 HOW TO DETERMINE BOLT STRENGTH Bolt Type Hexagon Head Bolt Normal Recess Bolt Deep Recess Bolt Stud Bolt Weld Bolt 4 Class 4T No Mark No Mark No Mark 5 5T 6 6T w/ Washer w/ Washer 7 7T 8 8T 9 9T 10 10T 11 11T B06431 2001 PRIUS (RM778U) Author: Date: 123 SS–2 SERVICE SPECIFICATIONS – STANDARD BOLT SS0ZT–01 SPECIFIED TORQUE FOR STANDARD BOLTS Specified torque Class Diameter mm Pitch mm Hexagon head bolt Hexagon flange bolt N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf 4T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 5 12.5 26 47 74 115 55 130 260 480 760 1,150 48 in.·lbf 9 19 35 55 83 6 14 29 53 84 – 60 145 290 540 850 – 52 in.·lbf 10 21 39 61 – 5T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 6.5 15.5 32 59 91 140 65 160 330 600 930 1,400 56 in.·lbf 12 24 43 67 101 7.5 17.5 36 65 100 – 75 175 360 670 1,050 – 65 in.·lbf 13 26 48 76 – 6T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 8 19 39 71 110 170 80 195 400 730 1,100 1,750 69 in.·lbf 14 29 53 80 127 9 21 44 80 125 – 90 210 440 810 1,250 – 78 in.·lbf 15 32 59 90 – 7T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 10.5 25 52 95 145 230 110 260 530 970 1,500 2,300 8 19 38 70 108 166 12 28 58 105 165 – 120 290 590 1,050 1,700 – 9 21 43 76 123 – 8T 8 10 12 1.25 1.25 1.25 29 61 110 300 620 1,100 22 45 80 33 68 120 330 690 1,250 24 50 90 9T 8 10 12 1.25 1.25 1.25 34 70 125 340 710 1,300 25 51 94 37 78 140 380 790 1,450 27 57 105 10T 8 10 12 1.25 1.25 1.25 38 78 140 390 800 1,450 28 58 105 42 88 155 430 890 1,600 31 64 116 11T 8 10 12 1.25 1.25 1.25 42 87 155 430 890 1,600 31 64 116 47 97 175 480 990 1,800 35 72 130 2001 PRIUS (RM778U) SS–3 SERVICE SPECIFICATIONS – STANDARD BOLT SS0ZU–01 HOW TO DETERMINE NUT STRENGTH Nut Type Present Standard Hexagon Nut Old Standard Hexagon Nut Cold Forging Nut Class Cutting Processed Nut 4N No Mark 5N (4T) No Mark (w/ Washer) No Mark (w/ Washer) No Mark 6N 6N 7N (5T) * 8N 8N 10N (7T) 10N No Mark 11N 11N 12N 12N *: Nut with 1 or more marks on one side surface of the nut. B06432 HINT: Use the nut with the same number of the nut strength classification or the greater than the bolt strength classification number when tightening parts with a bolt and nut. Example: Bolt = 4T Nut = 4N or more 2001 PRIUS (RM778U) SS–4 SERVICE SPECIFICATIONS – MAINTENANCE MAINTENANCE SS0MG–01 SERVICE DATA Front axle and suspension Ball joint vertical play Maximum 0 mm (0 in.) 2001 PRIUS (RM778U) Author: Date: 126 SS–5 SERVICE SPECIFICATIONS – MAINTENANCE SS0MH–04 TORQUE SPECIFICATION Part tightened Front seat x Body Front suspension sus ension member x Body (See page MA–7) Rear suspension member x Body 2001 PRIUS (RM778U) Bolt A Bolt B N·m kgf·cm ft·lbf 37 375 27 113 157 1,152 1,600 83 116 90 918 66 SS–6 SERVICE SPECIFICATIONS – ENGINE MECHANICAL ENGINE MECHANICAL SS174–03 SERVICE DATA at 250 rpm STD 728 kPa (7.4 kgf/cm2, 106 psi) Minimum 534 kPa (5.4 kgf/cm2, 77 psi) Difference between each cylinder 98 kPa (1.0 kgf/cm2, 14 psi) Compression pressure at cold Intake Exhaust No. 06 No. 08 No. 10 No. 12 No. 14 No. 16 No. 18 No. 20 No. 22 No. 24 No. 26 No. 28 No. 30 No. 32 No. 34 No. 36 No. 38 No. 40 No. 42 No. 44 No. 46 No. 48 No. 50 No. 52 No. 54 No, 56 No. 58 No. 60 No. 62 No. 64 No. 66 No. 68 No. 70 No. 72 No. 74 Valve lifter for repair part Valve clearance Ignition timing 7 – 15° BTDC @ idle w/ Cooling fan off Idle speed Chain and timing sprocket Chain tensioner slipper and vibration damper 0.17 – 0.23 mm (0.007 – 0.009 in.) 0.27 – 0.33 mm (0.011 – 0.013 in.) 5.060 mm (0.1992 in.) 5.080 mm (0.2000 in.) 5.100 mm (0.2008 in.) 5.120 mm (0.2016 in.) 5.140 mm (0.2024 in.) 5.160 mm (0.2031 in.) 5.180 mm (0.2039 in.) 5.200 mm (0.2047 in.) 5.220 mm (0.2055 in.) 5.240 mm (0.2063 in.) 5.260 mm (0.2071 in.) 5.280 mm (0.2079 in.) 5.300 mm (0.2087 in.) 5.320 mm (0.2094 in.) 5.340 mm (0.2102 in.) 5.360 mm (0.2110 in.) 5.380 mm (0.2118 in.) 5.400 mm (0.2126 in.) 5.420 mm (0.2134 in.) 5.440 mm (0.2142 in.) 5.460 mm (0.2150 in.) 5.480 mm (0.2157 in.) 5.500 mm (0.2165 in.) 5.520 mm (0.2173 in.) 5.540 mm (0.2181 in.) 5.560 mm (0.2189 in.) 5.580 mm (0.2197 in.) 5.600 mm (0.2205 in.) 5.620 mm (0.2213 in.) 5.640 mm (0.2220 in.) 5.660 mm (0.2228 in.) 5.680 mm (0.2236 in.) 5.700 mm (0.2244 in.) 5.720 mm (0.2252 in.) 5.740 mm (0.2260 in.) 1,000 ± 50 rpm (A/C OFF) 1,200 ± 50 rpm (A/C ON) Chain length at 16 links Camshaft timing sprocket wear (w/ chain) Crankshaft timing sprocket wear (w/ chain) Maximum 123.2 mm (4.850 in.) Minimum 96.2 mm (3.787 in.) Minimum 50.5 mm (1.988 in.) Wear Maximum 1.0 mm (0.039 in.) 2001 PRIUS (RM778U) Author: Date: 128 SS–7 SERVICE SPECIFICATIONS Cylinder head Valve guide bushing Warpage Cylinder brock side Intake manifold side Exhaust manifold side Valve seat Refacing angle Contacting angle Contacting width Valve guide bushing bore diameter Valve face angle Stem diameter Valve Stem oil clearance Margin thickness Valve lifter Maximum 0.05 mm (0.0020 in.) Maximum 0.01 mm (0.0394 in.) Maximum 0.01 mm (0.0394 in.) 20°, 45°, 75° 45° 1.0 – 1.4 mm (0.039 – 0.055 in.) 9.685 – 9.706 mm (0.38130 – 0.38213 in.) STD 9.735 – 9.756 mm (0.38327 – 0.38493 in.) O/S 0.05 5.010 – 5.030 mm (0.19724 – 0.19803 in.) 9.0 – 9.4 mm (0.354 – 0.370 in.) STD Intake Exhaust Minimum Intake Exhaust 89.25 mm (3.5138 in.) 87.90 mm (3.4606 in.) 88.95 mm (3.5020 in.) 87.60 mm (3.4488 in.) 44.5° Intake 4.970 – 4.985 mm (0.19567 – 0.19626 in.) Exhaust 4.965 – 4.980 mm (0.19547 – 0.19606 in.) STD Intake 0.025 – 0.060 mm (0.00098 – 0.00236 in.) Exhaust 0.030 – 0.065 mm (0.00118 – 0.00256 in.) Maximum Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) STD 1.00 – 1.15 mm (0.039 – 0.045 in.) Minimum 0.7 mm (0.028 in.) Deviation Maximum 1.6 mm (0.063 in.) Angle (Reference) Maximum 2° Free length 59.77 mm (2.353 in.) Installed tension at 32.5 mm (1.280 in.) 140 – 154 N (14.3 – 15.7 kgf, 31.5 – 34.6 lbf) Maximum working tension at 23.9 mm (0.941 in.) 180 – 198 N (18.4 – 20.2 kgf, 40.4 – 44.8 lbf) Lifter diameter Lifter bore diameter Oil clearance 30.966 – 30.976 mm (1.21913 – 1.21952 in.) 31.009 – 31.025 mm (1.22082 – 1.22145 in.) STD 0.031 – 0.059 mm(0.00122 – 0.00232 in.) Maximum 0.1 mm (0.004 in.) Thrust clearance STD Maximum STD Maximum No. 1 Others Maximum Journal oil clearance Journal diameter Camshaft ENGINE MECHANICAL Inside diameter Protrusion height Valve overall length Valve spring – Circle run out Cam lobe height STD Intake Exhaust Minimum Intake Exhaust 0.040 – 0.095 mm (0.0016 – 0.0037 in.) 0.11 mm (0.0043 in.) 0.040 – 0.095 mm (0.00157 – 0.00374 in.) 0.115 mm (0.00453 in.) 34.449 – 34.465 (1.35626 – 1.35689 in.) 22.949 – 22.965 (0.90350 – 0.90413 in.) 0.03 mm (0.0012 in.) 42.310 – 42.410 mm (1.62637 – 1.66968 in.) 44.046 – 44.146 mm (1.73409 – 1.73803 in.) 42.16 mm (1.6598 in.) 43.90 mm (1.7283 in.) Intake manifold Warpage Maximum 0.10 mm (0.0039 in.) Exhaust manifold Warpage Maximum 0.70 mm (0.0276 in.) 2001 PRIUS (RM778U) Author: Date: 129 SS–8 SERVICE SPECIFICATIONS – ENGINE MECHANICAL Cylinder head surface warpage Cylinder bore diameter Cylinder block Maximum STD Maximum Main journal bore diameter Mark 0 Mark 1 mark 2 Mark 3 Mark 4 Mark 5 Mark 6 12 pointed head bearing cap sub–assembly bolt diameter at tension portion STD Minimum 0.05 mm (0.0020 in.) 75.000 – 75.013 mm (2.95275 – 2.95326 in.) 75.013 mm (2.95326 in.) 50.000 – 50.003 mm (1.96850 – 1.96862 in.) 50.003 – 50.005 mm (1.96862 – 1.96870 in.) 50.005 – 50.007 mm (1.96870 – 1.96878 in.) 50.007 – 50.010 mm (1.96878 – 1.96889 in.) 50.010 – 50.012 mm (1.96889 – 1.96897 in.) 50.012 – 50.014 mm (1.96897 – 1.96905 in.) 50.014 – 50.016 mm (1.96905 – 1.96913 in.) 7.3 – 7.5 mm (0.287 – 0.295 in.) 7.3 mm (0.287 in.) Piston diameter Piston and Piston ring at 27 mm (1.063 in.) from the piston head Piston oil clearance STD Maximum Piston ring groove clearance Piston ring end gap STD No. 1 No. 2 Oil Maximum No. 1 No. 2 Oil Thrust clearance Connecting rod thickness Connecting rod bearing center wall thickness Reference Connecting rod 74.945 – 74.955 mm (2.95058 – 2.95098 in.) 0.045 – 0.068 mm (0.00177 – 0.00268 in.) 0.08 mm (0.0031 in.) 0.030 – 0.070 mm (0.0012 – 0.0028 in.) 0.22 – 0.32 mm (0.0087 – 0.0126 in.) 0.32 – 0.47 mm (0.0126 – 0.0185 in.) 0.15 – 0.45 mm (0.0059 – 0.0177 in.) 0.88 mm (0.0346 in.) 1.03 mm (0.0406 in.) 0.92 mm (0.0362 in.) STD 0.16 – 0.36 mm (0.0063 – 0.0142 in.) Maximum 0.36 mm (0.0142 in.) 19.788 – 19.840 mm (0.779 – 0.781 in.) Mark 1 Mark 2 Mark 3 Connecting rod oil clearance STD Maximum Rod out–of–alignment Maximum per 100 mm (3.94 in.) Rod twist Maximum per 100 mm (3.94 in.) Bushing inside diameter Piston pin diameter Bushing oil clearance STD Maximum Connecting rod bolt diameter at tension portion STD Minimum 1.488 – 1.492 mm (0.0586 – 0.0587 in.) 1.492 – 1.496 mm (0.0587 – 0.0589 in.) 1.496 – 1.500 mm (0.0589 – 0.0591 in.) 0.016 – 0.040 mm (0.0006 – 0.0016 in.) 0.06 mm (0.0024 in.) 0.05 mm (0.0020 in.) 0.05 mm (0.0020 in.) 18.010 – 18.019 mm (0.7091 – 0.7094 in.) 17.988 – 18.007 mm (0.7086 – 0.7089 in.) 0.009 – 0.015 mm (0.0003 – 0.0006 in.) 0.05 mm (0.0020 in.) 6.6 – 6.7 mm (0.260 – 0.264 in.) 6.4 mm (0.252 in.) 2001 PRIUS (RM778U) Author: Date: 130 SS–9 SERVICE SPECIFICATIONS Thrust clearance Thrust washer thickness Main journal oil clearance Main journal diameter Reference Crankshaft Main bearing center wall thickness Reference Crank pin diameter Circle run out Main journal taper and out–of round Crank pin taper and out–of round – ENGINE MECHANICAL STD 0.090 – 0.190 mm (0.00354 – 0.00748 in.) Maximum 0.30 mm (0.012 in.) 2.430 – 2.480 mm (0.09567 – 0.09764 in.) STD 0.010 – 0.023 mm (0.0004 – 0.0009 in.) Maximum 0.07 mm (0.0028 in.) Mark 0 Mark 1 Mark 2 Mark 3 Mark 4 Mark 5 45.988 – 45.990 mm (1.81054 – 1.81062 in.) 45.990 – 45.992 mm (1.81062 – 1.81071 in.) 45.992 – 45.994 mm (1.81071 – 1.81078 in.) 45.994 – 45.996 mm (1.81078 – 1.81086 in.) 45.996 – 45.998 mm (1.81086 – 1.81094 in.) 45.998 – 46.000 mm (1.81094 – 1.81102 in.) Mark 1 Mark 2 Mark 3 Mark 4 1.992 – 1.995 mm (0.07843 – 0.07854 in.) 1.995 – 1.998 mm (0.07854 – 0.07866 in.) 1.998 – 2.001 mm (0.07866 – 0.07878 in.) 2.001 – 2.004 mm (0.07878 – 0.07890 in.) 39.992 – 40.000 mm (1.5745 – 1.5748 in.) Maximum 0.03 mm (0.0012 in.) Maximum 0.02 mm (0.0008 in.) Maximum 0.02 mm (0.0008 in.) 2001 PRIUS (RM778U) Author: Date: 131 SS–10 SERVICE SPECIFICATIONS – ENGINE MECHANICAL SS175–03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Plug x Timing chain cover 15 150 11 Chain vibration damper x Cylinder block 9.0 92 80 in .·lbf Chain tensioner 9.0 92 80 in .·lbf 11 24 11 24 11 24 11 112 245 112 245 112 245 112 8 18 8 18 8 18 8 55 561 41 7.5 11 76 112 66 in .·lbf 8 Oil control valve 8.0 82 71 in .·lbf Crankshaft pulley x Crankshaft 128 1,300 94 Cylinder head cover x Cylinder 10 100 7 45 52 52 459 530 530 33 38 38 29.4 Turn 90° Turn 90° 300 Turn 90° Turn 90° 22 Turn 90° Turn 90° Timing chain cover Bolt A Bolt B Bolt C Bolt D Bolt E Nut F Nut G RH engine mounting bracket x Timing chain cover Crankshaft position sensor x Timing chain cover RH engine mounting insulator Cylinder head x Cylinder block Bolt A Bolt B Bolt A Bolt B Nut 1st 2nd 3rd Water bypass pipe x Cylinder head 9.0 92 80 in .·lbf No. 1 camshaft bearing cap x Cylinder head 23 235 17 No. 2 camshaft bearing cap x Cylinder head 12.7 130 10 Camshaft timing sprocket x Camshaft 64 650 47 Valve timing controller assembly x Camshaft 64 650 47 Intake manifold x Cylinder head 20 204 15 Exhaust manifold x Cylinder head 27 275 20 Upper heat insulator x Exhaust manifold 8.0 82 71 in .·lbf 27 275 20 62 32 630 330 46 24 Exhaust manifold stay x Cylinder block Front exhaust pipe x Tailpipe Bolt A Bolt B Connecting rod cap x Connecting rod 1st 2nd 15 Turn 90° 150 Turn 90° 11 Turn 90° Bearing cap x Cylinder block 1st 2nd 22 Turn 90° 220 Turn 90° 16 Turn 90° Oil pan No. 1 x Cylinder block 24 245 18 Oil strainer x Oil pan No. 1 11 112 8 Oil pan No. 2 x Oil pan No. 1 9.0 92 80 in.·lbf Oil filter union x Oil pan No. 1 30 306 21 12.7 130 9 Knock sensor x Cylinder block 44 450 33 Water bypass pipe x Cylinder block 9.0 90 80 in.·lbf Flywheel x Crankshaft 84 857 62 Damper spring x Flywheel 16 163 12 Engine coolant drain plug x Cylinder block 2001 PRIUS (RM778U) SS–11 SERVICE SPECIFICATIONS – EMISSION CONTROL EMISSION CONTROL SS17E–01 TORQUE SPECIFICATION Part tightened PCV valve x Cylinder head cover N·m kgf·cm ft·lbf 27 275 20 2001 PRIUS (RM778U) Author: Date: 133 SS–12 SERVICE SPECIFICATIONS – SFI SFI SS102–07 SERVICE DATA Fuel pump Resistance Injector Resistance Injection volume Difference between each cylinder Fuel leakage at 20°C (68°F) at 21 °C (68 °F) 0.2 – 3.0 Ω 13.4 – 14.2 Ω 36 – 46 cm3 (2.1 – 2.8 cu in.) per 15 sec. 10 cm3 (0.7 cu in.) or less 1 drop or less per 12 minutes Mass air flow meter Resistance at –20°C (–4°F) at 20°C (68°F) at 60°C (140°F) THA – E2 THA – E2 THA – E2 Throttle control motor Resistance at 20°C (68°F) M+ – M– 0.3 – 100 Ω Throttle position sensor Resistance at 20°C (68°F) VC – E2 1.2 – 3.2 kΩ VSV for EVAP Resistance at 20°C (68°F) 27 – 33 Ω VSV for CCV Resistance at 20°C (68°F) 25 – 30 Ω VSV for Purge flow switching valve Resistance at 20°C (68°F) 33 – 39 Ω VSV for HCAC Resistance at 20°C (68°F) 33 – 39 Ω Resistance at –20°C (–4°F) at 0°C (32°F) at 20°C (68°F) at 40°C (104°F) at 60°C (140°F) at 80°C (176°F) ECT sensor 13.6 – 18.4 kΩ 2.21 – 2.69 kΩ 0.49 – 0.67 kΩ 10 – 20 kΩ 4 – 7 kΩ 2 – 3 kΩ 0.9 – 1.3 kΩ 0.4 – 0.7 kΩ 0.2 – 0.4 kΩ Vacuum sensor for HCAC Power sorce voltage 4.5 – 5.5 V Vapor pressure sevsor Power sorce voltage Output voltage 4.5 – 5.5 V 3.0 – 3.6 V Heated oxygen sensor Heater coil resistance Accelerator pedal position sensor Fuel cut rpm Resistance at 20°C (68°F) Fuel return rpm at 20°C (68°F) Vcp1 – Ep1 Vcp2 – Ep2 11 – 16 Ω 1.5 – 6.0 kΩ 1,400 rpm 2001 PRIUS (RM778U) Author: Date: 134 SS–13 SERVICE SPECIFICATIONS – SFI SS103–06 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Fuel pump assembly x Fuel tank 4.0 40 35 in.·lbf Delivery pipe x Cylinder head 19 194 14 Throttle body x Intake manifold 20 204 15 Camshaft timing oil control valve x Cylinder head 7.5 76 66 in.·lbf Knock sensor x Cylinder block 44 450 33 Heated oxygen sensor (Bank1 sensor1) x Exhaust manifold 44 440 31 Heated oxygen sensor (Bank1 sensor2) x Exhaust pipe 44 440 31 2001 PRIUS (RM778U) SS–14 SERVICE SPECIFICATIONS – COOLING COOLING SS176–03 SERVICE DATA Drive belt Tension (Reference) Thermostat Valve opening temperature New belt Used belt at 90°C (199°F) Radiator cap Electric cooling fan Relief valve opening pressure Amperage 110 ± 11 lbf 67 ± 10 lbf 80.0 – 84.0°C (176 – 183°F) 8.5 mm (0.345 in.) or more STD 74 – 103 kPa (0.75 – 1.05 kgf/cm2, 10.7 – 14.9 psi) Minimum 79 kPa (0.8kgf/cm2, 11.5 psi) STD 9.2 – 11.0 A 2001 PRIUS (RM778U) Author: Date: 136 SS–15 SERVICE SPECIFICATIONS – COOLING SS177–02 TORQUE SPECIFICATION Part tightened Drain plug N·m kgf·cm ft·lbf 12.7 130 9 Water pump x Timing chain cover 11 110 8 Pump pulley x Water pump 15 150 11 Water inlet x Cylinder block 9.0 90 80 in.·lbf Electric cooling fan assembly x Radiator 7.5 76 66 in.·lbf Fan motor x Fan shroud 2.65 27 23 in.·lbf Fan x Fan motor 6.4 66 57 in.·lbf 2001 PRIUS (RM778U) SS–16 SERVICE SPECIFICATIONS – LUBRICATION LUBRICATION SS178–01 SERVICE DATA at idle speed at 3,000 rpm Oil pressure Side clearance Oil pump Tip clearance Body clearance STD Maximum STD Maximum STD Maximum 29 kPa (0.3 kgf/cm2,4.3 psi) or more 150 – 550 kPa (1.5 – 5.6 kgf/cm2, 22 – 80 psi) 0.03 – 0.09 mm (0.0012 – 0.0035 in.) 0.15 mm (0.0059 in.) 0.060 – 0.180 mm (0.0024 – 0.0071 in.) 0.28 mm (0.0110 in.) 0.250 – 0.325 mm (0.00984 – 0.01280 in.) 0.425 mm (0.01673 in.) 2001 PRIUS (RM778U) Author: Date: 138 SS–17 SERVICE SPECIFICATIONS – LUBRICATION SS179–02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Oil pressure switch x Cylinder block 13 130 9 Oil drain plug x Oil pan 38 387 28 Plug x Oil pump body 25 255 18 8.8 10.3 90 105 78 in.·lbf 8 Oil pump cover x Timing chain cover 2001 PRIUS (RM778U) Bolt Screw SS–18 SERVICE SPECIFICATIONS – IGNITION IGNITION SS17A–03 SERVICE DATA Recommended spark plug Spark plug Electrode gap DENSO NGK STD Maximum SK16R11 IFR5A11 1.0 – 1.1 mm (0.039 – 0.043 in.) 1.2 mm (0.047 in.) Camshaft position sensor Resistance at cold at hot 1,630 – 2,740 Ω 2,065 – 3,225 Ω Crankshaft position sensor Resistance at cold at hot 985 – 1,600 Ω 1,265 – 1,890 Ω 2001 PRIUS (RM778U) Author: Date: 140 SS–19 SERVICE SPECIFICATIONS – IGNITION SS17B–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Spark plug x Cylinder head 18 184 13 Ignition coil x Cylinder head 9.0 92 80 in.·lbf Camshaft position sensor x Cylinder head 8.0 82 71 in.·lbf Crankshaft position sensor x Cylinder block 7.5 76 66 in.·lbf 2001 PRIUS (RM778U) SS–20 SERVICE SPECIFICATIONS – HYBRID VEHICLE CONTROL HYBRID VEHICLE CONTROL SS1HH–02 SERVICE DATA Resistance HV battery thermistor Converter Output current Water temperature switch Service plug Auxiliary battery at 25 °C (77 °F) 1↔2 3↔4 5↔6 7↔8 9 ↔ 10 Service plug lever Voltage 9 – 11 kΩ 9 – 11 kΩ 9 – 11 kΩ 9 – 11 kΩ 9 – 11 kΩ 100 A or less at 48 °C (118.4 °F) or less at more than 55 °C (131 °F) No continuity Continuity Close Stand up Continuity No continuity at 20 °C (68 °F) 12.5 – 12.9 V 2001 PRIUS (RM778U) Author: Date: 142 SS–21 SERVICE SPECIFICATIONS – HYBRID VEHICLE CONTROL SS1HI–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Battery module x Battery carrier 4.0 40 35 in.·lbf Battery clamp bolt x Battery carrier 23 230 16 RH battery bracket x Battery carrier 23 230 16 Battery ECU x Battery carrier 3.3 33 29 in.·lbf Busber module x Battery module 6.0 61 53 in.·lbf Power cable x SMR 5.0 50 44 in.·lbf Service plug assembly x Battery carrier 6.0 61 53 in.·lbf 18 8.0 7.0 6.0 185 80 70 61 13 71 in.·lbf 62 in.·lbf 53 in.·lbf Battery bracket 18 185 13 HV battery x Body 18 185 13 Battery carrier catch bracket x Battery bracket 8.0 80 71 in.·lbf Bracket x Converter & Inverter assembly 25 255 18 Upper inverter cover x Converter & inverter assembly 2.5 25 22 in.·lbf Inverter reservoir tank x Converter & inverter assembly 8.0 82 71 in.·lbf Converter & inverter assembly x Body 21 214 15 Ground cable x Radiator upper support 8.0 82 71 in.·lbf Power cable for MG1 x Converter & inverter assembly 7.0 71 62 in.·lbf Connector cover x Converter & inverter assembly 20 204 15 19.5 8.0 199 82 14 71 in.·lbf Inverter terminal cover x Converter & inverter assembly 8.0 82 71 in.·lbf HV water pump x Body 7.0 70 62 in.·lbf Inverter radiator x Body 8.0 82 71 in.·lbf Water temperature switch x Inverter radiator 7.4 75 65 in.·lbf Blower assembly x Body 5.0 51 44 in.·lbf Lower quarter ventilator duct x Body 4.0 41 35 in.·lbf Inner ventilator duct x Body 4.0 41 35 in.·lbf HV ECU x Body 6.0 60 53 in.·lbf Battery cover x Battery carrier (See page HV–9) Power cable for MG2 x Converter & inverter assembly (See page HV–22) 2001 PRIUS (RM778U) Bolt A Bolt B Bolt C Screw Bolt A Bolt B SS–22 SERVICE SPECIFICATIONS – HYBRID TRANSAXLE HYBRID TRANSAXLE SS1HE–01 SERVICE DATA Differential case side bearing preload (Starting torque) (Turning torque 60 rpm) New bearing: 0.98 – 1.57 N·m (9.99 – 16.01 kgf·cm, 8.67 – 13.90 in.·lbf) Reused bearing: 0.49 – 0.78 N·m (5.00 – 7.95 kgf·cm, 4.43 – 6.90 in.·lbf) 0.78 – 1.37 N·m (7.95 – 13.97 kgf·cm, 6.90 – 12.13 in.·lbf) Differential preload adjusting shim thickness Mark 1 Mark 2 Mark 3 Mark 4 Mark 50 Mark 51 Mark 52 Mark 53 Mark 54 Mark 55 Mark 56 Mark 57 Mark 58 Mark 59 Mark 60 Mark 61 Mark 62 Mark 63 Mark 64 Mark 65 Mark 66 Mark 67 Mark 68 Mark 69 Mark 70 Mark 19 Mark 20 – Mark 22 Mark 23 1.80 mm (0.0709 in.) 1.83 mm (0.0720 in.) 1.86 mm (0.0732 in.) 1.89 mm (0.0744 in.) 1.92 mm (0.0756 in.) 1.94 mm (0.0764 in.) 1.96 mm (0.0772 in.) 1.98 mm (0.0780 in.) 2.00 mm (0.0787 in.) 2.02 mm (0.0795 in.) 2.04 mm (0.0803 in.) 2.06 mm (0.0811 in.) 2.08 mm (0.0819 in.) 2.10 mm (0.0827 in.) 2.12 mm (0.0835 in.) 2.14 mm (0.0843 in.) 2.16 mm (0.0850 in.) 2.18 mm (0.0858 in.) 2.20 mm (0.0866 in.) 2.22 mm (0.0874 in.) 2.24 mm (0.0882 in.) 2.26 mm (0.0890 in.) 2.28 mm (0.0898 in.) 2.30 mm (0.0906 in.) 2.32 mm (0.0913 in.) 2.34 mm (0.0921 in.) 2.37 mm (0.0933 in.) 2.40 mm (0.0945 in.) 2.43 mm (0.0957 in.) 2.46 mm (0.0969 in.) Counter driven gear side bearing preload (Starting torque) (Turning torque 60 rpm) New bearing: 3.81 – 6.10 N·m (38.85 – 62.20 kgf·cm, 33.72 – 53.99 in.·lbf) Reused bearing: 1.91 – 3.03 N·m (19.48 – 30.90 kgf·cm, 16.91 – 26.82 in.·lbf) 3.29 – 6.66 N·m (33.55 – 67.91 kgf·cm, 29.12 – 58.95 in.·lbf) 2001 PRIUS (RM778U) Author: Date: 144 SS–23 SERVICE SPECIFICATIONS – HYBRID TRANSAXLE Counter driven gear preload adjusting shim thickness Mark 1 Mark 2 Mark 3 Mark 50 Mark 51 Mark 52 Mark 53 Mark 54 Mark 55 Mark 56 Mark 57 Mark 58 Mark 59 Mark 60 Mark 61 Mark 62 Mark 63 Mark 64 Mark 65 Mark 66 Mark 67 Mark 68 Mark 69 Mark 70 Mark 18 Mark 19 Mark 20 Mark 21 Mark 22 1.25 mm (0.0492 in.) 1.28 mm (0.0504 in.) 1.31 mm (0.0516 in.) 1.34 mm (0.0528 in.) 1.36 mm (0.0535 in.) 1.38 mm (0.0543 in.) 1.40 mm (0.0551 in.) 1.42 mm (0.0559 in.) 1.44 mm (0.0567 in.) 1.46 mm (0.0575 in.) 1.48 mm (0.0583 in.) 1.50 mm (0.0591 in.) 1.52 mm (0.0598 in.) 1.54 mm (0.0606 in.) 1.56 mm (0.0614 in.) 1.58 mm (0.0622 in.) 1.60 mm (0.0630 in.) 1.62 mm (0.0638 in.) 1.64 mm (0.0646 in.) 1.66 mm (0.0654 in.) 1.68 mm (0.0661 in.) 1.70 mm (0.0669 in.) 1.72 mm (0.0677 in.) 1.74 mm (0.0685 in.) 1.76 mm (0.0693 in.) 1.79 mm (0.0705 in.) 1.82 mm (0.0717 in.) 1.85 mm (0.0728 in.) 1.88 mm (0.0740 in.) Mark 1 Mark 2 Mark 3 Mark 4 Mark 5 Mark 6 Mark 7 Mark 8 Mark 9 Mark 10 Mark 11 Mark 12 1.00 mm (0.0394 in.) 1.20 mm (0.0472 in.) 1.40 mm (0.0551 in.) 1.60 mm (0.0630 in.) 1.80 mm (0.0709 in.) 2.00 mm (0.0787 in.) 2.20 mm (0.0866 in.) 2.40 mm (0.0945 in.) 2.60 mm (0.1024 in.) 2.80 mm (0.1102 in.) 3.00 mm (0.1181 in.) 3.20 mm (0.1260 in.) Mark A Mark B Mark C Mark D Mark E Mark F Mark G Mark H Mark J Mark K Mark L 1.35 mm (0.0531 in.) 1.40 mm (0.0551 in.) 1.45 mm (0.0571 in.) 1.50 mm (0.0591 in.) 1.55 mm (0.0610 in.) 1.60 mm (0.0630 in.) 1.65 mm (0.0650 in.) 1.70 mm (0.0669 in.) 1.75 mm (0.0689 in.) 1.80 mm (0.0709 in.) 1.85 mm (0.0728 in.) Input shaft shim thickness Counter drive gear shim thickness Differential oil seal LH and RH drive in depth 2.7 ± 0.5 mm (0.11 ± 0.02 in.) Oil pressure 39.2 – 78.4 kPa (0.4 – 0.8 kgf/cm2, 5.7 – 11.4 psi) 2001 PRIUS (RM778U) Author: Date: 145 SS–24 SERVICE SPECIFICATIONS Differential side gear backlash Differential side gear washer thickness Sun gear bush diameter – HYBRID TRANSAXLE Standard 0.05 – 0.20 mm (0.0020 – 0.0079 in.) 0.95 mm (0.0374 in.) 1.00 mm (0.0394 in.) 1.05 mm (0.0414 in.) 1.10 mm (0.0433 in.) 1.15 mm (0.0453 in.) 1.20 mm (0.0472 in.) Standard 25.525 – 25.546 mm (1.00492 – 1.00575 in.) Maximum 25.596 mm (1.00771 in.) 2001 PRIUS (RM778U) Author: Date: 146 SS–25 SERVICE SPECIFICATIONS – HYBRID TRANSAXLE SS1HF–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Oil pump cover x MG2 assembly 5.5 56 49 in.·lbf Transaxle oil drain plug 49 498 36 Hybrid transaxle assembly x Engine 33 332 24 Coolant drain plug x MG1 assembly 39 400 29 Screw plug x MG1 assembly 12.7 130 9 Screw plug x MG2 assembly 24.5 250 18 Filler plug x MG2 assembly 39 400 29 MG1 assembly x MG2 assembly 25 250 18 Sleeve bracket x MG1 assembly 13 130 9 Lock clamp x MG1 assembly 5.4 55 48 in.·lbf Oil strainer x MG2 assembly 5.5 56 49 in.·lbf Oil pan x MG2 assembly 7.6 77 67 in.·lbf Parking shaft cover x MG2 assembly 13 130 10 Motor water jacket cover x MG2 assembly 5.5 56 49 Housing tube x MG1 assembly 15 152 11 Detent spring set bolt 10 100 7 Parking cover x MG2 assembly 5.5 56 49 in.·lbf Oil pump cover x plug 7.35 75 65 in.·lbf Wiring harness connector x MG2 assembly 5.5 56 49 in.·lbf Wiring harness connector x MG1 assembly 5.5 56 49 in.·lbf Water jacket union 50 510 37 High–voltage cable set bolt (3 under power cable cover) 18 183 13 High–voltage cable set bolt (3 outside) 5.5 56 49 in.·lbf Power cable cover x MG1 assembly 4.8 48 42 in.·lbf Mounting bracket x MG2 assembly 52 530 38 Shift lever assembly x Steering column 8 80 71 in.·lbf Differential case x Ring gear 87 90 64 2001 PRIUS (RM778U) SS–26 SERVICE SPECIFICATIONS – SUSPENSION AND AXLE SUSPENSION AND AXLE SS13W–06 SERVICE DATA Cold tire inflation pressure Front 240 kPa (2.4 kgf/cm2, 35 psi) Rear 230 kPa (2.3 kgf/cm2, 33 psi) Tire size: P175/65R14 84S Vehicle height P175/65R14 Front*1 Rear*2 Right–left error –0°26’ ± 45’ (–0.43° ± 0.75°) 45’ (0.75°) or less Right–left error 1°02’ ± 45’ (1.03° ± 0.75°) 45’ (0.75°) or less Right–left error 9°52’ ± 45’ (9.87° ± 0.75°) 45’ (0.75°) or less Camber Caster Front wheel alignment Steering axis inclination Toe–in (total) 191 mm (7.52 in.) 239 mm (9.41 in.) 0°06’ ± 12’ (0.1° ± 0.2°, 1 ± 2 mm, 0.04± 0.08 in.) Rack end length difference 1.5 mm (0.059 in.) or less Wheel angle Inside wheel Outside wheel: Reference Camber Rear wheel alignment F t axle Front l Front drive shaft F t suspension Front i R Rear axle l Right–left error 42°42’ ± 2° (42.70° ± 2°) 35°54’ (35.90°) –1°30’ ± 45’ (–0.93° ± 0.75°) 45’ (0.75°) or less 0°06’ ± 20’ (0.1° ± 0.33°) 1 ± 3.0 mm (0.04 ± 0.12 in.) Toe–in (total) Axle bearing backlash Maximum 0.05 mm (0.0020 in.) Axle hub deviation Maximum 0.07 mm (0.0028 in.) Drive shaft standard length LH RH 579.9 ± 5.0 mm (22.831 ± 0.197 in.) 836.9 ± 5.0 mm (32.949 ± 0.197 in.) Lower suspension arm ball joint turning torque 1.0 – 4.9 N·m (10 – 50 kgf·cm, 8.7 – 43 in.·lbf) Stabilizer bar link ball joint turning torque 0.05 – 1.0 N·m (0.5 – 10 kgf·cm, 0.4 – 8.7 in.·lbf) Axle bearing backlash Maximum 0.05 mm (0.0020 in.) Axle hub deviation Maximum 0.07 mm (0.0028 in.) *1: Front measuring point Measure the distance from the ground to the head center of the front side lower suspension arm mounting bolt. *2: Rear measuring point Measure the distance from the ground to the center of the rear axle beam mounting bolt. 2001 PRIUS (RM778U) Author: Date: 148 SS–27 SERVICE SPECIFICATIONS – SUSPENSION AND AXLE SS04X–12 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Hub nut 103 1,050 76 Tie rod end lock nut 74 750 55 Steering knuckle x Shock absorber 153 1,560 113 Steering knuckle x Brake caliper 107 1,090 79 Steering knuckle x Tie rod end 49 500 36 Axle hub x Drive shaft 216 2,200 159 Lower ball joint x Lower suspension arm 142 1,450 105 Lower ball joint x Steering knuckle 103 1,050 76 Steering knuckle x Dust cover 8.3 85 74 in.·lbf ABS speed sensor set bolt 8.0 82 71 in.·lbf Suspension support x Body 39 400 29 Suspension support x Piston rod 47 475 34 Flexible hose x Shock absorber 29 300 22 ABS speed sensor wire harness x Shock absorber 5.4 55 48 in.·lbf Lower suspension arm set bolt 137 1,397 101 113 157 1,152 1,600 83 116 Torque rod x Suspension member 100 1,030 74 Stabilizer bar bracket x Suspension member 19 194 14 Stabilizer bar link set nut 74 755 55 Hub nut 103 1,050 76 Axle hub set bolt 52 525 38 Shock absorber x Axle Beam 80 816 59 ABS speed sensor wire harness x Axle Beam 5.4 55 48 in.·lbf Spring bracket x Body 80 816 59 Shock absorber center nut 56 571 41 Parking brake cable set bolt 5.4 55 48 in.·lbf Toe control link x Body 90 918 66 Toe control link x Axle beam 90 918 66 Stabilizer bar set bolt 149 1,519 110 FRONT AXLE FRONT SUSPENSION Suspension member set bolt Front side Rear side REAR AXLE REAR SUSPENSION 2001 PRIUS (RM778U) SS–28 SERVICE SPECIFICATIONS – BRAKE BRAKE SS0LM–06 SERVICE DATA BRAKE PEDAL Brake pedal height from asphalt sheet 127 – 137 mm (5.08 – 5.48 in.) Brake pedal freeplay 1 – 6 mm (0.04 – 0.24 in.) Brake pedal reserve distance at 200 N (20 kgf, 45 Ibf) More than 85 mm (3.35 in.) PARKING BRAKE PEDAL Parking brake pedal travel at 294N (30 Kgf, 66.1 Ibf) 5 – 8 clicks FRONT BRAKE Front brake pad thickness Front brake pad thickness Front brake disc thickness STD 11.0 mm (0.433 in.) Minimum 1.0 mm (0.039 in.) STD 22.0 mm (0.984 in.) Front brake disc thickness Minimum 20.0 mm (0.906 in.) Front brake disc runout Maximum 0.05 mm (0.0020 in.) REAR BRAKE Drum brake shoe lining thickness Drum brake shoe lining thickness Rear brake drum inside diameter Rear brake drum inside diameter Rear brake drum to shoe clearance STD 4.0 mm (0.157 in.) Minimum 1.0 mm (0.039 in.) STD 200.0 mm (7.874 in.) Maximum 201.0 mm (7.913 in.) 0.6 mm (0.024 in.) 2001 PRIUS (RM778U) Author: Date: 150 SS–29 SERVICE SPECIFICATIONS – BRAKE SS0LN–06 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Pedal bracket x Reinforcement 14 143 10 Brake pedal x Pedal bracket 37 375 27 Pedal bracket x Reinforcement 14 143 10 Pedal bracket x Body 13 130 9 Brake pedal x Pedal bracket 32 327 24 Master cylinder x Pedal bracket 13 130 9 Master cylinder clevis lock nut 26 265 19 Hydraulic brake booster assembly x Body 19 194 14 Sub–bracket x Body 19 194 14 Reservoir bracket x Body 18 184 13 Reservoir x Bracket 7.5 77 66 in.·lbf Accumulator x Booster pump 54 550 36 Pressure switch assembly x Brake power supply bracket 7.8 80 69 in.·lbf Booster pump x Brake booster pump bracket No. 2 7.8 80 69 in.·lbf Pressure switch assembly x Brake booster pump bracket No. 1 7.8 80 69 in.·lbf Connector bracket x Pressure switch assembly 7.8 80 69 in.·lbf Pressure switch assembly x Brake booster pump bracket No. 2 7.8 80 69 in.·lbf Front disc brake caliper installation bolt 34 350 25 Bleeder plug 8.3 85 74 in.·lbf Front disc brake caliper x Flexible hose 30 310 22 Front disc brake torque plate x Steering knuckle 107 1,090 79 BRAKE PEDAL PARKING BRAKE PEDAL BRAKE MASTER CYLINDER HYDRAULIC BRAKE BOOSTER FRONT BRAKE REAR BRAKE Bleeder plug 8.5 87 75 in.·lbf Rear drum brake wheel cylinder x Backing plate 10 100 7 Brake actuator assembly x Body 19 195 14 Brake actuator x Actuator bracket 11 120 8 Front speed sensor installation bolt 8.0 82 71 in.·lbf Front speed sensor harness clamp bolt 5.5 56 49 in.·lbf Rear speed sensor harness clamp bolt 5.5 56 49 in.·lbf 15 155 11 BRAKE ACTUATOR SPEED SENSOR BRAKE LINE Brake line union nut 2001 PRIUS (RM778U) SS–30 SERVICE SPECIFICATIONS – STEERING STEERING SS16Y–09 SERVICE DATA STEERING WHEEL Steering wheel freeplay Maximum 30 mm (1.18 in.) Steering effort at idle speed Reference 6.5 N·m (65 kgf·cm, 58 in.·lbf) 2001 PRIUS (RM778U) Author: Date: 152 SS–31 SERVICE SPECIFICATIONS – STEERING SS16Z–08 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Adjusting nut 13 130 9 No. 2 tilt lever lock bolt 5.4 55 48 in.·lbf Tilt steering support lock nut 9.5 100 87 in.·lbf Main shaft lower dust seal 4.9 50 43 in.·lbf Column assembly set bolt and nut 25 260 19 No. 2 intermediate shaft assembly x Main shaft assembly 35 360 26 No. 2 intermediate shaft assembly x Intermediate extension 35 360 26 Shift lock computer sub–assembly 4.0 40 35 in.·lbf Steering wheel set nut 50 510 37 Steering wheel pad set screw (Torx screw) 8.8 90 78 in.·lbf 62 (83) 630 (850) 46 (61) Tie rod end lock nut 56 570 41 PS gear assembly set bolt 83 850 61 Stabilizer bar set bolt 19 190 14 Suspension member 137 142 1,400 1,450 101 105 Torque rod set nut 100 1,020 74 EMPS bracket set bolt 5.5 60 52 in.·lbf Lower suspension arm x Lower ball joint 142 1,450 105 Stabilizer bar link set nut 74 760 55 Tie rod end x Steering knuckle 49 500 36 TILT STEERING COLUMN POWER STEERING GEAR Rack end x Steering rack ( ): For use without SST 2001 PRIUS (RM778U) SS–33 SERVICE SPECIFICATIONS – BODY ELECTRICAL BODY ELECTRICAL SS02V–05 SERVICE DATA DAYTIME RUNNING RELAY (MAIN) (Wire harness side) 12 – Ground (Ignition switch OFF) No voltage 12 – Ground (Ignition switch ON) Battery voltage 9 – Ground (Engine Running) Battery voltage 3 – Ground (Constant) Battery voltage 6 – Ground (Constant) Battery voltage SPEEDOMETER (ON–VEHICLE) Standard indication (mph) Allowable range (mph) 20 18 – 22 40 38 – 42 60 59 – 63 80 79 – 83 100 99 – 104 120 119 – 125 Standard indication (km/h) Allowable range (km/h) 20 18 – 22 40 38 – 42 60 58 – 62 80 78 – 82 100 97 – 103 120 117 – 123 140 137 – 143 160 157 – 163 Float position mm (in.) Resistance (Ω) F: Approx. 25.2 (0.99) Approx. 430 1/2: Approx. 92.6 (3.65) Approx. 1000 – 2000 E: Approx. 169 (6.65) Approx. 5000 FUEL SENDER GAUGE DEFOGER SWITCH (Wire harness side) 1 – Ground (Ignition switch LOCK or ACC) No voltage 1 – Ground (Ignition switch ON) Battery voltage 8 – Ground (Constant) Battery voltage WIRELESSS DOOR LOCK CONTROL RECEIVER (Wire harness side) 5 – Ground (Constant) Battery voltage POWER MIRROR SWITCH (Wire harness side) 8 – Ground (Ignition switch LOCK) No voltage 8 – Ground (Ignition switch ACC or ON) Battery voltage RADIO RECEIVER (Wire harness side) 3 – Ground (Ignition switch LOCK) No voltage 3 – Ground (Ignition switch ACC or ON) Battery voltage 4 – Ground (Constant) Battery voltage CENTER CLUSTER SWITCH (Wire harness side) 1 – Ground (Ignition switch ACC or ON) Battery voltage 2001 PRIUS (RM778U) Author: Date: 155 SS–34 SERVICE SPECIFICATIONS – BODY ELECTRICAL 1 – Ground (Ignition switch LOCK) No voltage 2 – Ground (Constant) Battery voltage TRANSPONDER KEY ECU (Wire harness side) 1 – Ground (Constant) Battery voltage 2 – Ground (Ignition switch ON) Battery voltage 2001 PRIUS (RM778U) Author: Date: 156 SS–35 SERVICE SPECIFICATIONS – BODY BODY SS1HM–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf – – – 1.7 17 15 in.·lbf – – – Hood x Hinge 13 130 9 Hood lock x Body 8.3 85 74 in.·lbf – – – Outside view mirror x Door 7.8 80 69 in.·lbf Window regulator arm x Door 4.9 50 43 in.·lbf Window regulator body x Door 8.3 85 74 in.·lbf FRONT BUMPER Side marker x Bumper HOOD FRONT DOOR Door lock x Door Bolt: 4.9 50 43 in.·lbf Door lock x Door Screw: 4.9 50 43 in.·lbf Outside handle x Door 5.4 55 48 in.·lbf Hinge x Body 43 440 32 in.·lbf Hinge x Door 43 440 32 in.·lbf Door lock striker x Body 23 230 17 in.·lbf REAR DOOR – – – Window regulator x Door 5.4 55 48 in.·lbf Door lock x Door 4.9 50 43 in.·lbf Outside handle x Body 5.4 55 48 in.·lbf Hinge x Body 25 260 19 Hinge x Door 30 310 22 Door lock striker x Body 23 230 17 LUGGAGE COMPARTMENT DOOR AND HINGE – – – Door lock x Door 5.4 55 48 in.·lbf Hinge x Door 8.3 85 74 in.·lbf Door lock striker x Body 5.4 55 48 in.·lbf FRONT WIPER AND WASHER – – – Wiper arm x Wiper link 26 270 20 5.4 55 48 in.·lbf Wiper motor x Wiper link Bolt: Wiper motor x Wiper link Nut: 17 175 13 Wiper link x Outer front cowl top panel 7.4 75 65 in.·lbf Outer front cowl top panel x Body 5.4 55 48 in.·lbf – – – 2.9 30 26 in.·lbf INSTRUMENT PANEL – – – Front passenger airbag assembly x Reinforcement 20 204 15 FRONT SEAT – – – Seat cushion frame x Body 37 380 27 Seatback assembly x Seat cushion frame 43 440 32 REAR SEAT – – – 7.9 81 70 in.·lbf ROOF HEADLINING Inner rear view mirror x Body Seatback assembly x Body 2001 PRIUS (RM778U) Author: Date: 157 SS–36 SERVICE SPECIFICATIONS – BODY SEAT BELT – – – Outer belt shoulder anchor x Anchor adjuster 42 430 31 Anchor adjuster x Body 42 430 31 Seat belt floor anchor x Body 42 430 31 4.9 50 43 in.·lbf 42 430 31 Inner belt x Seat cushion frame 41 420 30 Rear seat belt retractor x Body 42 430 31 Rear seat inner belt x Body 42 430 31 CRS Tether anchor bracket x Body 20 200 14 CRS Anchor bracket sub–assembly x Body 31 320 23 SPOILER – – – 5.0 51 44 in.·lbf Retractor x Body Retractor x Body Rear spoiler x Body Upper bolt: Lower bolt: 2001 PRIUS (RM778U) Author: Date: 158 DI–3 DIAGNOSTICS – ENGINE DI00H–16 PRE–CHECK 1. (a) DIAGNOSIS SYSTEM Description
When troubleshooting OBDII vehicles, the only difference from the usual troubleshooting procedure is that you connect to the vehicle the OBDII scan tool complying with SAE J1978 or TOYOTA hand– held tester, and read off various data output from the vehicle’s ECM.
FI0534 TOYOTA Hand–Held tester OBDII regulations require that the vehicle’s on– board computer lights up the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in the emission control system/components or in the powertrain control components which affect vehicle emissions, or a malfunction in the computer. In addition to the MIL lighting up when a malfunction is detected, the applicable Diagnostic Trouble Code (DTC) prescribed by SAE J2012 are recorded in the ECM memory (See page DI–14). If the malfunction does not reoccur in 3 consecutive trips, the MIL goes off automatically but the DTCs remain recorded in the ECM memory.
When DTC P3190, P3191 are detected and the remain of the fuel is little, the computer judges the cause as a fuel shortage, and after the next trip, when the supply of fuel is confirmed, it turns off MIL, but the memory of DTC still remains.

DLC3 2001 PRIUS (RM778U) I12054 To check the DTCs, connect the TOYOTA hand– held tester or OBDII scan tool to Data Link Connector 3 (DLC3) on the vehicle. The TOYOTA hand– held tester or OBDII scan tool also enables you to erase the DTCs and check freezed frame data and various forms of engine data. (For operating instructions, see the OBDII scan tool’s instruction book.) DTCs include SAE controlled codes and manufacturer controlled codes. SAE controlled codes must be set as prescribed by the SAE, while manufacturer controlled codes can be set freely by the manufacturer within the prescribed limits (See DTC chart on page DI–14). DI–4 DIAGNOSTICS
– ENGINE The diagnosis system operates in normal mode during normal vehicle use. It also has a check mode for technicians to simulate malfunction symptoms and troubleshoot. Most DTCs use 2 trip detection logic* to prevent erroneous detection, and ensure thorough malfunction detection. By switching the ECM to check mode when troubleshooting, the technician can cause the MIL to light up for a malfunction that is only detected once or momentarily (TOYOTA hand–held tester only). (See step 2)
*2 trip detection logic: When a malfunction is first detected, the malfunction is temporarily stored in the ECM memory (1st trip). If the same malfunction is first detected again during the second drive test, this second detection causes the MIL to light up (2nd trip). (However, the IG switch must be turned OFF between the 1st trip and the 2nd trip.)
Freeze frame data: Freeze frame data records the engine condition when a misfire (DTC P0300 – P0304) or fuel trim malfunction (DTC P0171, P0172) or other malfunction (first malfunction only), is detected.
Because freeze frame data records the engine conditions (fuel system, calculated load, engine coolant temperature, fuel trim,engine speed, vehicle speed, etc.) when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. Priorities for troubleshooting: If troubleshooting priorities for multiple DTCs are given in the applicable DTC chart, these should be followed. If no instructions are given troubleshoot DTCs according to the following priorities. (1) DTCs other than fuel trim malfunction (DTC P0171, P0172), and misfire (DTC P0300 – P0304). (2) Fuel trim malfunction (DTC P0171, P0172). (3) Misfire (DTC P0300 – P0304). 2001 PRIUS (RM778U) DI–5 DIAGNOSTICS (b) – ENGINE Check the DLC3. The vehicle’s ECM uses ISO 9141–2 for communication. The terminal arrangement of DLC3 complies with SAE J1962 and matches the ISO 9141–2 format. N09214 Terminal No. Connection / Voltage or Resistance Condition 7 Bus  Line / Pulse generation During transmission 4 Chassis Ground / ↔ Body Ground 1 Ω or less Always 5 Signal Ground / ↔ Body Ground 1 Ω or less Always 16 Battery Positive / ↔ Body Ground 9 – 14 V Always HINT: If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the cable of the TOYOTA hand–held tester or OBDII scan tool to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side.
If communication is normal when the tool is connected to another vehicle, inspect DLC3 on the original vehicle.
If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department listed in the tool’s instruction manual. 2. (a) FI2547 2001 PRIUS (RM778U) INSPECT DIAGNOSIS (Normal Mode) Check the MIL (1) The MIL comes on when the ignition switch is turned ON and the engine is not running. HINT: If the MIL does not light up, troubleshoot the combination meter (See page BE–42). (2) When the engine started, the MIL should go off. If the lamp remains on, the diagnosis system has detected a malfunction or abnormality in the system. (b) Check the DTC. NOTICE:
If there is no DTC in the normal mode, check the 1st trip DTC using Continuous Test Result function (Mode 7 for SAE J1979) or the TOYOTA hand–held tester or OBDII scan tool. DI–6 DIAGNOSTICS
– ENGINE TOYOTA hand–held tester only: When the diagnosis system is switched from normal mode to check mode, it erases all DTCs and freezed frame data recorded in normal mode. So before switching modes, always check the DTCs and freezed frame data, and note them down. (1) Prepare the TOYOTA hand–held tester or OBDII scan tool (complying with SAE J1978). (2) Connect the TOYOTA hand–held tester or OBDII scan tool to DLC3 under the instrument panel lower pad. (3) Turn the ignition switch ON and turn the TOYOTA hand–held tester or OBDII scan tool switch ON. (4) Use the TOYOTA hand–held tester or OBDII scan tool to check the DTCs and freezed frame data; note them down. (For operating instructions, see the OBDII scan tool’s instruction book.) (5) See step 4 to confirm the details of the DTCs. NOTICE:
When simulating symptoms with an OBDII scan tool (excluding TOYOTA hand–held tester) to check the DTCs, use normal mode. For code on the DTC chart subject to ”2 trip detection logic”, perform the following either action.
Turn the ignition switch OFF after the symptom is simulated the first time. Then repeat the simulation process again. When the problem has been simulated twice, the MIL lights up and the DTCs are recorded in the ECM.
Check the 1st trip DTC using Mode 7 (Continuous Test Results) for SAE J1979. (c) Clear the DTC. The DTCs and freezed frame data will be erased by either action. (1) Operating the TOYOTA hand–held tester or OBDII scan tool (complying with SAE J1978) to erase the codes. (See the OBDII scan tool’s instruction book for operating instructions.) (2) Disconnecting the battery terminals or EFI fuse. NOTICE: If the TOYOTA hand–held tester switches the ECM from the normal mode to the check mode or vice–versa, or if the ignition switch is turned from ON to ACC or OFF during check mode, the DTCs and freezed frame data will be erased. 2001 PRIUS (RM778U) DI–7 DIAGNOSTICS – ENGINE 3. INSPECT DIAGNOSIS (Check Mode) TOYOTA hand–held tester only: Compared to the normal mode, the check mode has an increased sensitivity to detect malfunctions. Furthermore, the same diagnostic items which are detected in the normal mode can also be detected in the check mode. (a) Check the DTC (1) Initial conditions:
Battery positive voltage 11 V or more.
Throttle valve fully closed.
Transmission in ”P” or ”N” position.
A/C switched OFF. (2) Turn the ignition switch OFF. (3) Prepare the TOYOTA hand–held tester. (4) Connect the TOYOTA hand–held tester to DLC3 under the instrument panel lower pad. (5) Turn the ignition switch ON and switch the TOYOTA hand–held tester ON. (6) Flashing ON OFF 0.13 Second FI3605 2001 PRIUS (RM778U) Switch the TOYOTA hand–held tester normal mode to check mode. (Check that the MIL flashes.) NOTICE: If the TOYOTA hand–held tester switches the ECM from the normal mode to the check mode or vice–versa, or if the ignition switch is turned from ON to ACC or LOCK during check mode, the DTCs and freezed frame data will be erased. (7) Switch the engine. (The MIL goes out after the engine start.) (8) Simulate the conditions of the malfunction described by the customer. NOTICE: Leave the ignition switch ON until you have checked the DTC, etc. (9) After simulating the malfunction conditions, use the TOYOTA hand–held tester diagnosis selector to check the DTCs and freezed frame data, etc. HINT: Take care not to turn the ignition switch OFF. Turning the ignition switch OFF switches the diagnosis system from check mode to normal mode. so all DTCs, etc. are erased. (10) After checking the DTC, inspect the applicable circuit. DI–8 DIAGNOSTICS – ENGINE 4. FAIL–SAFE CHART If any of the following codes is recorded, the ECM enters fail–safe mode. DTC No. Fail–Safe Operation Fail–Safe Deactivation Conditions P0100 Ignition timing fixed at 5° BTDC Returned to normal condition P0110 Intake air temp. is fixed at 20°C (68°F) Returned to normal condition P0115 Engine coolant temp. is fixed at 80°C (176°F) Returned to normal condition P0120 VTA is fixed at 0° The following condition must be repeated at least 2 times consecutively 0.1 V
VTA
0.95 V P0135 P0141 The heater circuit in which an abnormality is detected is turned off Ignition switch OFF P0325 Max. timing retardation Ignition switch OFF P1300 P1305 P1310 P1315 Fuel cut IGF signal is detected for 2 consecutive ignitions 5. CHECK FOR INTERMITTENT PROBLEMS TOYOTA hand–held tester only: By putting the vehicle’s ECM in check mode, 1 trip detection logic is possible instead of 2 trip detection logic and sensitivity to detect open circuits is increased. This makes it easier to detect intermittent problems. (1) Clear the DTC (See step 3). (2) Set the check mode (See step 3). (3) Perform a simulation test (See page IN–30). (4) Check the connector and terminal (See page IN–41). (5) Handle the connector (See page IN–41). 6. BASIC INSPECTION When the malfunction code is not confirmed in the DTC check, troubleshooting should be performed in the order for all possible circuits to be considered as the causes of the problems. In many cases, by carrying out the basic engine check shown in the following flow chart, the location causing the problem can be found quickly and efficiently. Therefore, use of this check is essential in engine troubleshooting. 1 Is battery positive voltage 11 V or more when engine is stopped? NO Charge or replace battery. NO Go to step 6. YES 2 Does engine start? YES 2001 PRIUS (RM778U) DI–9 DIAGNOSTICS 3 – ENGINE Check air filter. PREPARATION: Remove the air filter. CHECK: Visual check that the air filter is not dirty or excessive oily. HINT: If necessary, clean the air filter with compressed air. First blow from inside thoroughly, then blow from outside of the air filter. EM9891 NG Repair or replace. OK 4 Check engine idle speed. PREPARATION: (a) Warm up engine to normal operating temperature. (b) Switch off all accessories. (c) Switch off A/C. (d) Shift transmission into P position. (e) Connect the TOYOTA hand–held tester or OBDII scan tool to DLC3 on the vehicle. (f) Transit to inspection mode. CHECK: Use CURRENT DATA to check the idle speed. OK: Idle speed: 950 – 1,050 rpm NG OK 2001 PRIUS (RM778U) Proceed to problem symptoms table on page DI–22. DI–10 DIAGNOSTICS 5 – ENGINE Check ignition timing. PREPARATION: (a) Warm up engine to normal operating temperature. (b) Shift transmission into P position. (c) Keep the engine speed at idle. (d) Using SST, connect terminals TE1 and E1 of DLC1. SST 09843–18020 (e) Using a timing light, connect the tester to the ignition coil connector wire (See page EM–11). (f) Transit to inspection mode. CHECK: Check ignition timing. OK: Ignition timing: 7 – 15° BTDC at idle TC CG NG A04438 A13924 A14466 Proceed to page IG–1 and continue to troubleshoot. OK Proceed to problem symptoms table on page DI–22. 6 Check fuel pressure. A14060 2001 PRIUS (RM778U) PREPARATION: (a) Be sure that enough fuel is in the tank. (b) Connect the TOYOTA hand–held tester to the DLC3. (c) Turn the ignition switch ON and push the TOYOTA hand– held tester main switch ON. (d) Use the ACTIVE TEST mode to operate the fuel pump. (e) Please refer to the TOYOTA hand–held tester operator’s manual for further details. (f) If you have no TOYOTA hand–held tester, connect the positive (+) and negative (–) leads from the battery to the fuel pump connector (See page SF–6). CHECK: Check for fuel pressure in the fuel inlet hose when it is pinched off. HINT: At this time, you will hear a fuel flowing noise. DI–11 DIAGNOSTICS NG – ENGINE Proceed to page SF–6 and continue to troubleshoot. OK 7 Check for spark. PREPARATION: (a) Remove the ignition coil (See page IG–5). (b) Remove the spark plug. (c) Install the spark plug to ignition coil and connect the ignition coil connector to ignition coil. (d) Disconnect the injector connector. (e) Be sure to ground the screw of the spark plug securely. CHECK: Check if spark occurs while engine is being cranked. NOTICE:
Do not crash the electrode gap.
To prevent excess fuel being injected from the injectors during this test, don’t crank the engine for more than 5 – 10 seconds at a time. NG OK Proceed to problem symptoms table on page DI–22. 2001 PRIUS (RM778U) Proceed to page IG–1 and continue to troubleshoot. DI–12 DIAGNOSTICS – ENGINE 7. ENGINE OPERATING CONDITION NOTICE: The values given below for ”Normal Condition” are representative values, so a vehicle may still be normal even if its value varies from those listed here. So do not decide whether a part is faulty or not solely according to the ”Normal Condition” here. (a) CARB mandated signals. TOYOTA hand–held tester display Measurement Item Normal Condition* FUEL SYS #1 Fuel System Bank 1 OPEN: Air–fuel ratio feedback stopped CLOSED: Air–fuel ratio feedback operating Idling after warming up: CLOSED CALC LOAD Calculator Load: Current intake air volume as a proportion of max. intake air volume Idling: 5.4 – 19.2 % Racing without load (2,250rpm): 6.9 – 16.2 % Engine Coolant Temp. Sensor Value After warming up: 80 – 95°C (176 – 203°F) COOLANT TEMP. SHORT FT #1 Short–term Fuel Trim Bank 1 0 ± 20% LONG FT #1 Long–term Fuel Trim Bank 1 0 ± 20% ENGINE SPD Engine Speed Idling: 1,000 rpm VEHICLE SPD Vehicle Speed Vehicle Stopped: 0 km/h (0 mph) IGN ADVANCE Ignition Advance: Ignition Timing of Cylinder No. 1 Idling: BTDC 7 – 15° Intake Air Temp. Sensor Value Equivalent to Ambient Temp. Air Flow Rate Through Mass Flow Meter Idling: 1.11 – 4.38 gm/sec. Racing without load (2,250 rpm): 3.38 – 7.88 gm/sec. Voltage Output of Throttle Position Sensor Calculated as a percentage: 0 V → 0%, 5 V → 100% Throttle Fully Closed: 0 – 5 % Throttle Fully Open: 90 – 100 % O2S B1, S1 Voltage Output of Heated Oxygen Sensor Bank 1, Sensor 1 Idling: 0.1 – 0.9 V O2FT B1, S1 Heated Oxygen Sensor Fuel Trim Bank 1, Sensor 1 (Same as SHORT FT #1) O2S B1, S2 Voltage Output of Heated Oxygen Sensor Bank 1, Sensor 2 INTAKE AIR MAF/AFM THROTTLE POS 0 ± 20 % Driving at 50 km/h (31 mph): 0.1 – 0.9 V ∗: If no conditions are specifically stated for ”ldling”, it means the shift lever is at P position, the A/C switch is OFF and all accessory switches are OFF. (b) TOYOTA Enhanced Signals. TOYOTA hand–held tester display Measurement Item Normal Condition* MISFIRE RPM Engine RPM for first misfire range Misfire 0: 0 rpm MISFIRE LOAD Engine load for first misfire range Misfire 0: 0 g/r Fuel injection time for cylinder No.1 Idling: 1.0 – 3.0 ms INJECTOR CYL#1, CYL#2, CYL#3, CYL#4 Abnormal revolution variation for each cylinder 0% IGNITION Total number of ignition for every 1,000 revolutions 0 – 2,000 FUEL PUMP Fuel Pump Signal Idling: ON EVAP (PURGE) VSV EVAP VSV Signal VSV operating: ON VAPOR PRESS VSV Vapor Pressure VSV Signal VSV operating: ON Total Fuel Trim Bank 1: Average value for fuel trim system of bank 1 Idling: 0.8 – 1.2 V TOTAL FT B1 2001 PRIUS (RM778U) DI–13 DIAGNOSTICS – ENGINE O2 LR B1, S1 * Heated Oxygen Sensor Lean Rich Bank 1, Sensor 1 Response time for oxygen sensor output to switch from lean to rich Idling after warmed up: 0 – 1,000 msec. O2 RL B1, S1 * Heated Oxygen Sensor Rich Lean Bank 1, Sensor 1 Response time for oxygen sensor output to switch from rich to lean Idling after warmed up: 0 – 1,000 msec. *: If no conditions are specifically stated for ”ldling”, it means the shift lever is at P position, the A/C switch is OFF and all accessory switches are OFF. 2001 PRIUS (RM778U) DI–14 DIAGNOSTICS – ENGINE DI6UT–02 DIAGNOSTIC TROUBLE CODE CHART HINT:  Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument or other factors. If a malfunction code is displayed during the DTC check in check mode, check the circuit for that code listed in the table below. For details of each code, turn to the page referred to under the ’’See page ’’ for the respective ’’DTC No.’’ in the DTC chart.  When the ignition switch is ON and ”READY” indicator light is OFF, the bulb check of the ”MIL” is performed (”MIL” is ON). When ”MIL” is ON, but the DTC of the engine is not memorized, it may be because of HV control system abnormality, so check HV control system beforehand. SAE CONTROLLED: DTC No. Detection Item Trouble Area MIL*1 Memory P0100 (DI–23) Mass Air Flow Circuit Malfunction  Open or short in mass air flow meter circuit  Mass air flow meter  ECM   P0101 (DI–27) Mass Air Flow Circuit Range/ Performance Problem  Mass air flow meter   P0110 (DI–28) Intake Air Temp. Circuit Malfunction  Open or short in intake air temp. sensor circuit  Intake air temp. sensor (built into mass air flow meter)  ECM   P0115 (DI–32) Engine Coolant Temp. Circuit Malfunction  Open or short in engine coolant temp. sensor circuit  Engine coolant temp. sensor  ECM   P0116 (DI–36) Engine Coolant Temp. Circuit Range/Performance Problem  Cooling system  Engine coolant temp. sensor   P0120 (DI–38) Throttle/Pedal Position Sensor/ Switch ”A” Circuit Malfunction  Open or short in throttle position sensor circuit  Throttle position sensor  ECM   P0121 (DI–43) Throttle/Pedal Position Sensor/ Switch ”A” Circuit Range/Performance Problem  Throttle position sensor  ECM   Insufficient Coolant Temp. for Closed Loop Fuel Control  Open or short in heated oxygen sensor (bank 1 sensor 1) circuit  Heated oxygen sensor (bank 1 sensor 1)  Air induction system  Fuel pressure  Injector  Gas leakage on exhaust system  ECM   Thermostat Malfunction  Thermostat  Cooling system  Water temperature  ECM   Heated Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 1) (Except Calif.)  Open or short in heated oxygen sensor circuit  Heated oxygen sensor  Air induction system  EGR system  Fuel pressure  Injector  ECM   P0125 (DI–44) P0128 (DI–49) P0130 (DI–50) 2001 PRIUS (RM778U) DI–15 DIAGNOSTICS – ENGINE P0133 (DI–54) Oxygen Sensor Circuit Slow Response (Bank 1 Sensor 1)  Open or short in heated oxygen sensor circuit  Heated oxygen sensor  Air induction system  EGR system  Fuel pressure  Injector  ECM P0135 (DI–57) Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 1)  Open or short in heater circuit of heated oxygen sensor  Heated oxygen sensor heater  ECM   P0136 (DI–59) Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2)  Open or short in heated oxygen sensor circuit  Heated oxygen sensor   P0141 (DI–57) Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2)  Same as DTC No. P0135   System too Lean (Fuel Trim)  Air induction system  Injector blockage  Mass air flow meter  Engine coolant temp. sensor  Fuel pressure  Gas leakage on exhaust system  Open or short in heated oxygen sensor (bank 1 sensor 1) circuit  Heated oxygen sensor (bank 1 sensor 1)   P0172 (DI–61) System too Rich (Fuel Trim)  Injector leak, blockage  Mass air flow meter  Engine coolant temp. sensor  Ignition system  Fuel pressure  Gas leakage on exhaust system  Open or short in heated oxygen sensor (bank 1, 2 sensor 1) circuit  Heated oxygen sensor (bank 1, 2 sensor 1)  ECM   P0300 (DI–65) Random/Multiple Cylinder Misfire Detected P0301 (DI–65) Cylinder 1 Misfire Detected P0302 (DI–65) Cylinder 2 Misfire Detected   P0303 (DI–65) Cylinder 3 Misfire Detected P0304 (DI–65) Cylinder 4 Misfire Detected P0325 (DI–71) Knock Sensor 1 Circuit Malfunction (Bank 1)  Open or short in knock sensor 1 circuit  Knock sensor 1 (looseness)  ECM   Crankshaft Position Sensor ”A” Circuit Malfunction  Open or short in crankshaft position sensor circuit  Crankshaft position sensor  Signal plate (Timing belt guide)  Crankshaft timing pulley  ECM   P0171 (DI–61) P0335 (DI–74) 2001 PRIUS (RM778U)  Open or short in engine wire  Connector connection  Vacuum Vac m hose connection  Ignition system j  Injector  Fuel pressure  EGR system  Manifold absolute pressure sensor    Engine coolant temp. sensor  Compression pressure  Valve V l clearance l  Valve timing  ECM DI–16 DIAGNOSTICS – ENGINE P0340 (DI–76) Camshaft Position Sensor Circuit Malfunction  Open or short in camshaft position sensor circuit  Camshaft position sensor  Camshaft timing pulley  ECM   P0420 (DI–78) Catalyst System Efficiency Below Threshold (Bank 1)  Gas leakage on exhaust system  Open or short in heated oxygen sensor circuit  Heated oxygen sensor  Three–way catalytic converter   Evaporative Emission Control System Malfunction  Hose or tube cracked, hole, damaged or loose seal  Fuel tank cap incorrectly installed  Fuel tank cap cracked or damaged  Vacuum hose cracked, hole, blocked,damaged or disconnected  Fuel tank cracked, hole or damaged  Charcoal canister cracked, hole or damaged  Open or short in vapor pressure sensor circuit  Vapor pressure sensor  Fuel tank over fill check valve cracked or damaged  ECM    Vacuum hose cracked, hole, blocked damaged or disconnected  Open or short in vapor pressure sensor circuit  Vapor pressure sensor  Open or short in VSV circuit for EVAP  VSV for EVAP  Open or short in VSV circuit for vapor pressure sensor  VSV for vapor pressure sensor  Charcoal canister cracked, hole or damaged  Fuel tank over fill check valve cracked or damaged  ECM    Open or short in vapor pressure sensor circuit  Vapor V pressure sensor  ECM   P0440 (DI–81) P0441 (DI–87) Evaporative Emission Control System Incorrect Purge Flow P0446 (DI–87) Evaporative Emission Control System Vent Control Malfunction P0450 (DI–103) Evaporative Emission Control System Pressure Sensor Malfunction P0451 (DI–103) Evaporative Emission Control System Pressure Sensor Range/ Performance P0500 (DI–105) Vehicle Speed Sensor Malfunction  Combination meter  Open or short in vehicle speed sensor circuit  Vehicle speed sensor  ECM   P0505 (DI–107) Idle Control System Malfunction  Erectric throttle control system  Air induction system   *1: 


MIL lights up 2001 PRIUS (RM778U) DI–17 DIAGNOSTICS – ENGINE MANUFACTURER CONTROLLED: DTC No. (See Page) Detection Item Trouble Area MIL*1 Memory P1125 (DI–108) Throttle Control Motor Circuit Malfunction  Open or short in throttle control motor circuit  Throttle control motor  ECM   P1127 (DI–110) ETCS Actuator Power Source Circuit Malfunction  Open in ETCS power source circuit  ECM   P1128 (DI–112) Throttle Control Motor Lock Malfunction  Throttle control motor  Throttle body   P1129 (DI–114) Electric Throttle Control System Malfunction  Electric throttle control system  ECM   Igniter Circuit Malfunction (No.1)  Ignition system  Open or short in IGF1 and IGT1 circuit from No.1 ignition coil with igniter to ECM  No.1 ignition coil with igniter  ECM   Igniter Circuit Malfunction (No.2)  Ignition system  Open or short in IGF2 and IGT2 circuit from No.2 ignition coil with igniter to ECM  No.2 ignition coil with igniter  ECM   Igniter Circuit Malfunction (No.3)  Ignition system  Open or short in IGF2 and IGT3 circuit from No.3 ignition coil with igniter to ECM  No.3 ignition coil with igniter  ECM   P1315 (DI–115) Igniter Circuit Malfunction (No.4)  Ignition system  Open or short in IGF1 and IGT4 circuit from No.4 ignition coil with igniter to ECM  No.4 ignition coil with igniter  ECM   P1346 (DI–120) VVT Sensor/Camshaft Position Sensor Circuit Range/Performance Problem (Bank 1)  Mechanical system (Jumping teeth of timing belt, belt stretched)  ECM   P1349 (DI–121) VVT System Malfunction (Bank 1)  Valve timing  OCV  VVT controller assembly  ECM   P1430 (DI–127) Vacuum Sensor for Adsorber and Catalyst System Circuit Malfunction  Open or short circuit in vacuum sensor circuit  Vacuum sensor for HC adsorber and catalyst system  ECM   P1431 (DI–131) Vacuum Sensor for Adsorber and Catalyst System CIrcuit Rangel Performance Problem  Vacuum sensor for HC adsorber and catalyst system  Vacuum line   P1436 (DI–133) Variable Value Malfunction  Vacuum line  Actuator for HC adsorber and catalyst system  Front exhaust pipe   P1437 (DI–135) Vacuum Line Malfunction  Vacuum line  VSV for HC adsorber and catalyst system  Check valve   P1300 (DI–115) P1305 (DI–115) P1310 (DI–115) 2001 PRIUS (RM778U) DI–18 DIAGNOSTICS – ENGINE P1455 (DI–140) Vapor Reducing Fuel Tank System Leak Detected (Small Leak)  Hose and pipe  Heated oxygen sensor  Fuel system  VVT system  Ignition system  Mass air flow meter  ECM P1525 (DI–141) Resolver Circuit Malfunction  HV ECU  Engine ECU –  P1600 (DI–143) ECM BATT Malfunction  Open in back up power source circuit  ECM   P1633 (DI–145) ECU Malfunction (ETCS Circuit)  ECM   P1636 (DI–146) HV ECU Malfunction  HV ECU  Engine ECU   P1637 (DI–148) EGSTP Signal Malfunction  HV ECU  Engine ECU –  P1656 (DI–150) OCV Circuit Malfunction (for VVT–i)  Open or short in OCV circuit  OCV  ECM    Air induction system  Throttle body  Fuel pressure  Engine  Mass air flow meter  Out of fuel  Engine coolant temp. sensor  Crankshaft position sensor  Camshaft position sensor  ECM   P3190 (DI–153) P3191 (DI–153) Poor Engine Power Engine dose not start *1: 


MIL lights up 2001 PRIUS (RM778U)   DI–20 DIAGNOSTICS – ENGINE DI7SS–01 TERMINALS OF ECM E7 E8 E9 E10 F02094 Symbols (Terminal No.) BATT (E8 – 3) – E1 (E8 – 17) +B (E8 – 4) – E1 (E8 – 17) +BM (E7 – 6) – E1 (E8 – 17) Wiring Color R–W ↔ BR B ↔ BR GR ↔ BR Condition STD Voltage (V) Always 9 – 14 IG switch ON 9 – 14 Always 9 – 14 IGSW(E10 – 9) – E1(E8 – 17) B–W ↔ BR IG switch ON 9 – 14 MREL (E9 – 25) G–R ↔ BR IG switch ON 9 – 14 Y–R ↔ BR IG switch ON 4.5 – 5.5 IG switch ON Throttle valve fully closed 0.4 – 1.0 IG switch ON Throttle valve fully open 3.2 – 4.8 IG switch ON Accelerator pedal released 2.0 – 2.9 IG switch ON Accelerator pedal depressed 4.6 – 5.1 Idling, A/C switch OFF, Shift position in N or P position 0.5 – 3.0 Idling, Intake air temp. 20°C (68°F) 0.5 – 3.4 Idling, Engine coolant temp. 80°C (176°F) 0.2 – 1.0 – E1(E8 – 17) VC (E8 – 2) – E2 (E8 – 18) VTA (E8 – 23) – E2 (E8 – 18) VTA2 (E8 – 21) – E2 (E8 – 18) P ↔ BR L ↔ BR VG (E8 – 10) – EVG (E8 – 19) G↔R THA (E8 – 22) – E2 (E8 – 18) R–B ↔ BR THW (E8 – 14) – E2 (E8 – 18) W ↔ BR IG switch ON #10 (E8 – 5) – E01 (E7 – 21) Y ↔ W–B Idling IG switch ON #20 (E8 – 6) – E01 (E7 – 21) B–R ↔ W–B Idling IG switch ON #30 (E7 – 1) – E01 (E7 – 21) L–W ↔ W–B #40 (E7 – 2) – E01 (E7 – 21) R–W ↔ W–B IGT1 (E7 – 11) – E1 (E8 – 17) Idling IG switch ON 9 – 14 Pulse generation (See page DI–65) 9 – 14 Pulse generation (See page DI–65) 9 – 14 Pulse generation (See page DI–65) 9 – 14 Idling Pulse generation (See page DI–65) Y–G ↔ BR Idling Pulse generation (See page DI–115) IGT2 (E7 – 12) – E1 (E8 – 17) W ↔ BR Idling Pulse generation (See page DI–115) IGT3 (E7 – 13) – E1 (E8 – 17) G ↔ BR Idling Pulse generation (See page DI–115) 2001 PRIUS (RM778U) DI–21 DIAGNOSTICS IGT4 (E7 – 14) – E1 (E8 – 17) Y ↔ BR – ENGINE Idling IG switch ON IGF (E7 – 25) – E1 (E8 – 17) B–R ↔ BR Pulse generation (See page DI–115) 4.5 – 5.5 Idling Pulse generation (See page DI–115) G2 (E7 – 10) – NE
(E8 – 24) R↔G Idling Pulse generation (See page DI–74) NE+ (E8 – 16) – NE– (E8 – 24) R↔G Idling Pulse generation (See page DI–74) FC (E8 – 9) – E01 (E7 – 21) EVP1 (E7 – 29) – E1 (E8 – 17) G–R ↔ W–B IG switch ON 9 – 14 R–L ↔ BR IG switch ON 9 – 14 OX1A (E10 – 12) – E2 (E8 – 18) W ↔ BR Maintain engine speed at 2,500 rpm for 2 min. after warming up Pulse generation (See page DI–44) OX1B (E10 – 11) Y ↔ BR Maintain engine speed at 2,500 rpm for 2 min. after warming up Pulse generation (See page DI–44) – E2 (E8 – 18) HT1A (E10 – 1) – E1 (E8 – 17) P L ↔ BR P–L HT1B (E10 – 7) – E1 (E8 – 17) G Y ↔ BR G–Y KNK1 (E7 – 28) – E2 (E8 – 18) B ↔ BR SPD (E10 – 5) – E1 (E8 – 17) SPHV (E9 – 10) – E1 (E8 – 17) Idling IG switch ON Idling IG switch ON Below 3.0 9 – 14 Below 3.0 9 – 14 Idling Pulse generation (See page DI–71) V–W ↔ BR IG switch ON Rotate driving wheel slowly Pulse generation O ↔ BR IG switch ON Rotate driving wheel slowly Pulse generation (See page DI–105) ESTP (E9 – 16) – E1 (E8 – 17) R–Y ↔ BR Idling TAM (E9 – 23) – E2 (E8 – 18) W–G ↔ BR Outer air temp. –30 – 50°C W (E10 – 6) – E1 (E8 – 17) G R ↔ BR G–R ACT (E10 – 22) – E1 (E8 – 17) P G ↔ BR P–G OCV+ (E7 – 23) – OCV – (E7 – 24) Y R ↔ W–G Y–R W G Idling 9 – 14 0.7 – 3.2 9 – 14 IG switch ON Below 3.0 A/C switch OFF Below 2.0 A/C switch ON at idling 9 – 14 IG switch it h ON Pulse generation (See page DI–121) Idling Pulse generation (See page DI–108) M+ (E7 – 8) – E1 (E8 – 17) M– (E7 – 7) – E1 (E8 – 17) L ↔ BR P ↔ BR TC (E9 – 6) – E1 (E8 – 17) P–B ↔ BR IG switch ON 9 – 14 HCC (E9 – 20) – E1 (E8 – 17) B–W ↔ BR IG switch ON 9 – 14 IG switch ON 9 – 14 PTNK (E9 – 22) – E1 (E8 – 17) HCLS (E9 – 14) – E1 (E8 – 17) 2001 PRIUS (RM778U) L R ↔ BR L–R V W ↔ BR V–W Apply vacuum 4.0 kPa (30 mmHg, 1.2 in.Hg) Below 0.5 IG switch ON 3.3 – 3.9 Apply vacuum 67 kPa (500 mmHg, 19.7 in.Hg) 1.3 – 1.9 DI–23 DIAGNOSTICS – ENGINE DI6UV–03 CIRCUIT INSPECTION DTC P0100 Mass Air Flow Circuit Malfunction CIRCUIT DESCRIPTION The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, temparature sensor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and temparature sensor located in the intake air bypass of the housing detect any changes in the intake air temp. The hot wire is maintained at the set temp. by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the air flow meter. The circuit is constructed so that the platinum hot wire and temparature sensor provide a bridge circuit,with the power transistor controlled so that the potential of A and B remains equal to maintain the set temp. B+ Temparature Sensor Power Transister Platinum Hot wire A B Output Voltage FI6929 S05741 A06106 DTC No. P0100 DTC Detecting Condition Trouble Area Open or short in mass air flow meter circuit with more than 3 sec. engine speed 3,000 rpm or less
Open or short in mass air flow meter circuit
Mass air flow meter
ECM If the ECM detects DTC ”P0100” it operates the fail–safe function, keeping the ignition timing and injection volume constant and making it possible to drive the vehicle. HINT: After confirming DTC P0100 use the OBD II scan tool or TOYOTA hand–held tester to confirm the mass air flow ratio from ”CURRENT DATA”. Mass Air Flow Value (gm/sec.) 0.0 271.0 or more 2001 PRIUS (RM778U) Malfunction
Mass air flow meter power source circuit open
VG circuit open or short
E2G circuit open DI–24 DIAGNOSTICS – ENGINE WIRING DIAGRAM Engine Room J/B 12 1F EFI Relay EFI 4 IA2 G–R 1 2 3 1K W–B 5 3 3 1A B M1 Mass Air Flow Meter MAIN FL Block No. 1 1 1 B–G F13 F12 1 (Shielded) G 3 1 2 1B R 2 A F18 FL Block No. 2 25 E9 G–R ECM MREL 10 E8 VG 19 E8 EVG W–B J7 J/C B A A W–B A J9 J/C J1 J/C Battery IE A BR EB A14050 INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Connect OBD II scan tool or TOYOTA hand–held tester, and read value of mass air flow rate. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Turn ignition switch ON and push the OBD II scan tool or TOYOTA hand–held tester main switch ON. (c) Start the engine. CHECK: Read mass air flow rate on the OBD II scan tool or TOYOTA hand–held tester. RESULT: Mass air flow rate (gm/sec.) 2001 PRIUS (RM778U) Type I Type II 0.0 271.0 or more DI–25 DIAGNOSTICS 2 – ENGINE Type I Go to step 2. Type II Go to step 5. Check voltage of mass air flow meter power source. PREPARATION: (a) Disconnect the mass air flow meter connector. (b) Turn ignition switch ON. CHECK: Measure voltage between terminal 4 of mass air flow meter connector and body ground. OK: Voltage: 9 – 14 V ON 3 (+) BE6653 A01589 A01588 NG Check for open in harness and connector between EFI main relay (Marking: EFI) and mass air flow meter (See page IN–41). OK 3 Check voltage between terminal VG of ECM connector and body ground. START VG (+) A13618 PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Start the engine. CHECK: Measure voltage between terminal VG of ECM and body ground while engine is idling. OK: Voltage: 1.1 – 1.5 V (P position and A/C switch OFF) OK NG 2001 PRIUS (RM778U) Check and replace ECM (See page IN–41). DI–26 DIAGNOSTICS 4 – ENGINE Check for open and short in harness and connector between mass air flow meter and ECM (See page IN–41). NG Repair or replace harness or connector. OK Replace mass air flow meter. 5 Check continuity between terminal EVG of ECM connector and body ground. PREPARATION: Remove the ECM with connector still connected (See page SF–62). CHECK: Check continuity between terminal EVG of ECM connector and body ground. OK: Continuity (1 Ω or less) EVG A13619 NG Check and replace ECM (See page IN–41). OK 6 Check for open in harness and connector between mass air flow meter and ECM (See page IN–41). NG OK Replace mass air flow meter. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–28 DIAGNOSTICS – ENGINE DI6UX–02 DTC P0110 Intake Air Temp. Circuit Malfunction CIRCUIT DESCRIPTION (fig.1) 30 20 10 Resistance kΩ 5 Acceptable 3 2 1 0.5 0.3 0.2 0.1 – 20 (– 4) 0 32 20 68 40 104 60 140 80 176 100 212 Temp.°C (F°) FI4741 DTC No. P0110 The intake air temp. sensor is built into the mass air flow meter and senses the intake air temperature. A thermistor built in the sensor changes the resistance value according to the intake air temperature, the lower the intake air temperature, the greater the thermistor resistance value, and the higher the intake air temperature, the lower the thermistor resistance value (See fig.1). The air intake temperature sensor is connected to the ECM (See below). The 5V power source voltage in the ECM is applied to the intake air temp. sensor from the terminal THA via a resistor R. That is, the resistor R and the intake air temp. sensor are connected in series. When the resistance value of the intake air temp. sensor changes in accordance with changes in the intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. If the ECM detects the DTC ”P0110”, it operates the fail safe function in which the intake air temperature is assumed to be 20°C (68°F). DTC Detecting Condition Open or short in intake air temp. sensor circuit Trouble Area
Open or short in intake air temp. sensor circuit
Intake air temp. sensor (built into mass air flow meter)
ECM HINT: After confirming DTC P0110, use the OBD II scan tool or TOYOTA hand–held tester to confirm the intake air temperature from CURRENT DATA. Temperature Displayed Malfunction –40°C (–40°F) Open circuit 140°C (284°F) or more Short circuit 2001 PRIUS (RM778U) DI–29 DIAGNOSTICS – ENGINE WIRING DIAGRAM M1 Intake Air Temp. Sensor (Built into mass air flow meter) ECM 4 R–B 22 THA E8 5 BR 18 E8 5V R E2 E1 A00310 INSPECTION PROCEDURE HINT:

If DTC P0110 , P0115 and P0120 are output simultaneously, E2 (sensor ground) may be open. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Connect OBD II scan tool or TOYOTA hand–held tester, and read value of intake air temperature. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to DLC3. (b) Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand–held tester main switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Same as actual air intake temperature. HINT:
If there is open circuit, OBD II scan tool or TOYOTA hand–held tester indicates – 40°C (– 40°F).
If there is short circuit, OBD II scan tool or TOYOTA hand−held tester indicates 140°C (284°F) or more. NG OK Check for intermittent problems (See page DI–3). 2001 PRIUS (RM778U) –40°C (–40°F) ....Go to step 2. 140°C (284°F) or more ....Go to step 4. DI–30 DIAGNOSTICS 2 – ENGINE Check for open in harness or ECM. ON Connecting Intake Air Temp. Sensor 4 ECM 5 BE6653 A00347 A00348 PREPARATION: (a) Disconnect the intake temp. sensor connector. (b) Connect sensor wire harness terminals together. (c) Turn the ignition switch ON. CHECK: Read temp. value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temp. value: 140°C (284°F) or more OK Confirm good connection at sensor. If OK, replace intake air temp. sensor. NG 3 Check for open in harness or ECM. ON Intake Air Temp. Sensor ECM 5V 4 3 9 E2 E1 5 THA THA E2 PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Connect between terminals THA and E2 of the ECM connector. HINT: In take air temp. sensor connector is disconnected. Before checking, do a visual and contact pressure check for the ECM connector (See page IN–41). (c) Turn the ignition switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temperature value: 140°C (284°F) or more OK BE6653 A00360 A13620 A13621 NG Confirm good connection at ECM. If OK, check and replace ECM (See page IN–41). 2001 PRIUS (RM778U) Open in harness between terminals E2 or THA, repair or replace harness. DI–31 DIAGNOSTICS 4 – ENGINE Check for short in harness and ECM. ON ECM Intake Air Temp. Sensor 4 5 BE6653 A00362 PREPARATION: (a) Disconnect the mass air flow meter connector. (b) Turn the ignition switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temperature value: –40°C (–40°F) A00363 OK Replace mass air flow meter. NG 5 Check for short in harness or ECM. ON Intake Air Temp. Sensor ECM 5V THA E2 E1 PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Disconnect the E8 connector of the ECM. HINT: Intake air temp. sensor connector is disconnected. (c) Turn the ignition switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temperature value: –40°C (–40°F) E8 Connector A09085 A09091 OK NG Check and replace ECM (See page IN–41). 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–32 DIAGNOSTICS – ENGINE DI6UY–02 DTC P0115 Engine Coolant Temp. Circuit Malfunction CIRCUIT DESCRIPTION A thermistor built into the engine coolant temp. sensor changes the resistance value according to the engine coolant temp. The structure of the sensor and connection to the ECM is the same as in the intake air temp. circuit malfunction shown on page DI–28. If the ECM detects the DTC P0115, it operates fail safe function in which the engine coolant temperature is assumed to be 80°C (176°F). DTC No. P0115 Detection Item Trouble Area
Open or short in engine coolant temp. sensor circuit
Engine coolant temp. sensor
ECM Open or short in engine coolant temp. sensor circuit HINT: After confirming DTC P0115, use the OBD II scan tool or TOYOTA hand–held tester to confirm the engine coolant temp. from ”CURRENT DATA”. Temp. Displayed Malfunction –40°C (–40°F) Open circuit 140°C (284°F) or more Short circuit WIRING DIAGRAM E1 Engine Coolant Temp. Sensor ECM 5V 2 W 14 THW E8 1 BR 18 E8 R E2 E1 A00310 INSPECTION PROCEDURE HINT:

If DTC P0110, P0115 and P0120 are output simultaneously, E2 (sensor ground) may be open. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 2001 PRIUS (RM778U) DI–33 DIAGNOSTICS 1 – ENGINE Connect OBD II scan tool or TOYOTA hand–held tester, and read value of engine coolant temperature. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand–held tester main switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Same as actual engine coolant temperature HINT:
If there is open circuit, OBD II scan tool or TOYOTA hand–held tester indicates –40°C (–40°F).
If there is open circuit, OBD II scan tool or TOYOTA hand−held tester indicates 140°C (284°F) or more. NG –40°C (–40°F) ... Go to step 2. 140°C (284°F) or more ... Go to step 4. OK Check for intermittent problems (See page DI–3). 2 Check for open in harness or ECM. ON Water Temp. Sensor ECM 2 1 BE6653 A00365 Connecting A00366 PREPARATION: (a) Disconnect the engine coolant temp. sensor connector. (b) Connect the sensor wire harness terminals together. (c) Turn the ignition switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temperature value: 140°C (284°F) or more OK NG 2001 PRIUS (RM778U) Confirm good connection at sensor. If OK, replace engine coolant temp. sensor. DI–34 DIAGNOSTICS 3 – ENGINE Check for open in harness or ECM. ON Engine Coolant Temp. Sensor ECM 5V 2 THW E2 E1 1 E2 THW PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Connect between terminals THW and E2 of the ECM connector. HINT: Engine coolant temp. sensor connector is disconnected. Before checking, do a visual and contact pressure check for the ECM connector (See page IN–41). (c) Turn the ignition switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temperature value: 140°C (284°F) or more OK BE6653 A00370 A13622 Open in harness between terminals E2 or THW, repair or replace harness. A13623 NG Confirm good connection at ECM. If OK, check and replace ECM (See page IN–41). 4 Check for short in harness and ECM. ON Water Temp. Sensor 2 ECM 1 BE6653 A00372 PREPARATION: (a) Disconnect the engine coolant temp. sensor connector. (b) Turn the ignition switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temperature value: – 40°C (– 40°F) A00373 OK NG 2001 PRIUS (RM778U) Replace engine coolant temp. sensor. DI–35 DIAGNOSTICS 5 – ENGINE Check for short in harness or ECM. ON Engine Coolant Temp. Sensor ECM 5V THW E2 E1 PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Disconnect the E8 connector of the ECM. HINT: Engine coolant temp. sensor connector is disconnected. (c) Turn the ignition switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temperature value: –40°C (–40°F) OK E8 Connector A09085 A09091 NG Check and replace ECM (See page IN–41). 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–36 DIAGNOSTICS – ENGINE DI6UZ–03 DTC P0116 Engine Coolant Temp. Circuit Range/ Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0115 on page DI–32. DTC No. DTC Detecting Condition Trouble Area When the engine starts, the water temp. is –7°C (20°F) or less. And, 20 min. or more after the engine starts, the engine temp. sensor value is 5°C (41°F) or less (2 trip detection logic) When the engine starts, the water temp. is between –7°C (20°F) and 10°C (50°F). And, 5 min. or more after the engine starts, the engine coolant temp. sensor value is 5°C (41°F) or less. (2 trip detection logic) P0116 When the fluctuations in the engine coolant tempeerature are within 3 °C (37 °F)before and afrer the follwing conditions are met: 1. IDL OFF time  250 sec. 2. Vehicle speed change of 30 km/h (19 mph) or more occurs 10 times or more. 3. 35 °C (95 °F)
Engine coolant temperature when the ignition switch is turned ON < 60 °C (140 °F) 4. Intake air temperature after starting the engine  –6.7 °C (20 °F)
Engine coolant temp. sensor
Cooling system INSPECTION PROCEDURE HINT:
If DTC P0115 and P0116 are output simultaneously, engine coolant temp. sensor circuit may be open. Perform troubleshooting of DTC P0115 first. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction.
1 Are there any other codes (besides DTC P0116) being output? YES NO 2001 PRIUS (RM778U) Go to relevant DTC chart. DI–37 DIAGNOSTICS 2 – ENGINE Check thermostat (See page CO–9). NG OK Replace engine coolant temp. sensor. 2001 PRIUS (RM778U) Replace thermostat. DI–38 DIAGNOSTICS – ENGINE DI2DQ–07 DTC P0120 Throttle/Pedal Position Sensor/Switch ”A” Circuit Malfunction CIRCUIT DESCRIPTION Movable Range Movable Range *1 Usable Range Usable Range *2 *1 A02395 A02396 *2 E2 VTA2 DTC No. P0120 VTA Throttle Position Sensor Output Voltage (V) Throttle position sensor is mounted on the throttle body and it have the 2 sensors to detect the throttle opening angle and the malfunction of the throttle position sensor’s own. The voltage applied to the terminals VTA and VTA2 of the ECM changes between 0 V and 5 V in proportion to the opening angle of the throttle valve. The ECM judges the current opening angle of the throttle valve from these signals input from terminals VTA and VTA2, and the ECM controls the throttle motor to make the throttle valve angle properly in response to driving condition. If this DTC is stored, the ECM shuts down the power for the throttle motor, and the throttle valve is fully closed by the return spring. 5 VTA2 *1: Throttle valve fully closed *2: Throttle valve fully open 1.5 VTA 0 *1 70 125 *2 Usable Range Accelerator Pedal Opening Angle (deg) VC DTC Detecting Condition A02624 Trouble Area Condition (a), (b), (c), (d) or (e) continues for 2.0 seconds: (a) VTA
0.2 V (b) VTA2
0.625 V (c) VTA  4.8 V (d) When VTA  0.2 V and
2.0 V, and VTA2  4.97 V (e) VTA – VTA2
0.02 V
Open or short in throttle position sensor circuit
Throttle position sensor
ECM Condition (a) continues for 0.4 seconds: (a) VTA
0.2 V and VTA2
0.5 V HINT: After confirming DTC P0120, use the OBD II scan tool or TOYOTA hand–held tester to confirm the accelerator pedal opening position percentage. Accelerator pedal opening position expressed as percentage and voltage Accelerator pedal released Accelerator pedal depressed THROTTLE POS THROTTLE POS #2 0% 0V 0% 0V VC circuit open 0% 2.0 – 2.9 V 0% 4.6 – 5.1 V VTA circuit open or ground short 8 – 20 % 0V 64 – 96 % 0V VTA2 circuit open or ground short 100 % 5V 100 % 5V E2 circuit open 2001 PRIUS (RM778U) THROTTLE POS Trouble area THROTTLE POS #2 DI–39 DIAGNOSTICS – ENGINE WIRING DIAGRAM ECM Y–R 2 E8 VC 18 E8 E2 C T3 Throttle Position Sensor E2 VC J8 J/C C Y–R 1 BR 4 (Shielded) VTA2 L 21 E8 VTA2 P 23 E8 3 VTA1 2 VTA A J9 J/C A BR EB A14051 INSPECTION PROCEDURE HINT:
If DTCs P0110, P0115, P0120, P0450 and P1120 are output simultaneously, E2 (sensor ground) may be open. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting, it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction.
LEXUS hand–held tester: 1 Connect LEXUS hand–held tester, and read throttle valve opening percentage. PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand– held tester main switch ON. CHECK: Read the throttle valve opening percentage for VTA circuit and read the voltage for VTA2 circuit. FI7052 2001 PRIUS (RM778U) DI–40 DIAGNOSTICS – ENGINE OK: Accelerator Pedal Throttle valve opening position expressed as percentage (VTA) Voltage (VTA2) Released 64 – 96 % 4.6 – 5.1 V Depressed 8 – 20 % 2.0 – 2.9 V OK Check and replace ECM (See page IN–41). NG 2 Check voltage between terminals VC and E2 of ECM connector. ON VC (+) E2 (–) A13624 PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals VC and E2 of the ECM connector. OK: Voltage: 4.5 – 5.5 V NG Check and replace ECM (See page IN–41). OK 3 Check voltage between terminals VTA and E2, and VTA2 and E2 of ECM connector. PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals VTA and E2, and VTA2 and E2 of the ECM connector. OK: ON VTA2 VTA (+) E2 (–) A13625 Voltage A Accelerator l t pedal d l 2001 PRIUS (RM778U) VTA – E2 VTA2 – E2 Released 0.4 – 1.0 V 2.0 – 2.9 V Depressed 3.2 – 4.8 V 4.6 – 5.1 V DI–41 DIAGNOSTICS OK – ENGINE Check and replace ECM (See page IN–41). NG 4 Check throttle position sensor (See page SF–24). NG Replace throttle position sensor (See page SF–29). OK Check for open and short in harness and connector in VC, VTA, VTA2 and E2 circuits between ECM and throttle position sensor (See page IN–41). OBD II scan tool (excluding TOYOTA hand–held tester): 1 Check voltage between terminals VC and E2 of ECM connector. ON VC (+) E2 (–) A13624 PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals VC and E2 of the ECM connector. OK: Voltage: 4.5 – 5.5 V NG OK 2001 PRIUS (RM778U) Check and replace ECM (See page IN–41). DI–42 DIAGNOSTICS 2 – ENGINE Check voltage between terminals VTA and E2, and VTA2 and E2 of ECM connector. PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals VTA and E2, and VTA2 and E2 of the ECM connector. OK: ON VTA VTA2 (+) E2 (–) A13625 Voltage A Accelerator l t pedal d l OK VTA – E2 VTA2 – E2 Released 0.4 – 1.0 V 2.0 – 2.9 V Depressed 3.2 – 4.8 V 4.6 – 5.1 V Check and replace ECM (See page IN–41). NG 3 Check throttle position sensor (See page SF–24). NG Replace throttle position sensor (See page SF–29). OK Check for open and short in harness and connector in VC, VTA, VTA2 and E2 circuits between ECM and throttle position sensor (See page IN–41). 2001 PRIUS (RM778U) DI–44 DIAGNOSTICS – ENGINE DI6V2–03 DTC P0125 Insufficient Temp. for Closed Loop Fuel Control CIRCUIT DESCRIPTION To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three–way catalytic converter is used, but for the most efficient use of the three–way catalytic converter, the air–fuel ratio must be precisely controlled so that it is always close to the stoichiometric air–fuel ratio. The oxygen sensor has the characteristic whereby its output voltage changes suddenly in the vicinity of the stoichiometric air–fuel ratio. This is used to detect the oxygen concentration in the exhaust gas and provide feedback to the computer for control of the air–fuel ratio. When the air–fuel ratio becomes LEAN, the oxygen concentration in the exhaust increases and the oxygen sensor informs the ECM of the LEAN condition (small electromotive force: < 0.45 V). When the air–fuel ratio is RICHER than the stoichiometric air–fuel ratio the oxygen concentration in the exhaust gas in reduced and the oxygen sensor informs the ECM of the RICH condition (large electromotive force: > 0.45V). The ECM judges by the electromotive force from the oxygen sensor whether the air–fuel ratio is RICH or LEAN and controls the injection time accordingly. However, if malfunction of the oxygen sensor causes output of abnormal electromotive force, the ECM is unable to perform accurate air–fuel ratio control. The oxygen sensors include a heater which heats the zirconia element. The heater is controlled by the ECM. When the intake air volume is low (the temp. of the exhaust gas is low) current flows to the heater to heat the sensor for accurate oxygen concentration detection. Atmosphere Ideal Air–Fuel Mixture Platinum Electrode Solid Electrolyte (Zirconia Element) Platinum Electrode Heater Coating (Ceramic) Cover Output Voltage Flange Richer – Air Fuel Ratio – Leaner Exhaust Gas P21242 FI7210 A04485 DTC No. P0125 DTC Detecting Condition After the engine is warmed up, oxygen sensor (bank 1 sensor 1) output does not indicate RICH (
0.45 V) even once when conditions (a), (b), and (c) continue for at least 50 sec. (a) Engine speed: 800 rpm or more (b) Vehicle speed: 40 – 100 km/h (25 – 62 mph) (c) 20 sec. or more after starting engine 2001 PRIUS (RM778U) Trouble Area
Fuel system
Air induction system
Injector
Ignition system
Gas leakage on exhaust system
Open or short in heated oxygen sensor (bank 1 sensor 1) circuit
Heated oxygen sensor (bank 1 sensor 1)
ECM DI–45 DIAGNOSTICS – ENGINE HINT: After confirming DTC P0125, use the OBD II scan tool or TOYOTA hand−held tester to confirm voltage output of oxygen sensor (bank 1 sensor 1) from "CURRENT DATA". If voltage output of oxygen sensor (bank 1 sensor 1) is less than 0.1 V, oxygen sensor (bank 1 sensor 1) circuit may be open or short. WIRING DIAGRAM Engine Room J/B 12 1F 1 EFI EFI Relay 5 G–R 3 1A 3 H3 Bank 1 Sensor 1 4 B 2 G–R P–L B (Shielded) 2 FL Block No. 1 1 1 F13 F12 3 W 7 IK1 P–L 1 IE1 6 IK1 W 2 IE1 1 IK1 BR E2 1 E10 HT1A P–L (Shielded) W 12 E10 OX1A B W–B C A C A W–B BR B D J22 4 BR E J23 J1 J/C IE J/C E J23 BR 16 E10 E11 IP1 12 B 2 A 22 IE1 (Shielded) J4 J/C J7 J/C 1 Battery 18 E8 BR 1 13 1F FL MAIN Block No. 2 ECM 25 E9 MREL 3 1K 2 2 1B B–G 4 IA2 E J23 (Shielded) H9 Bank 1 Sensor 2 Y 3 1 G–Y BR 11 E10 OX1B 7 E10 HT1B A14052 2001 PRIUS (RM778U) DI–46 DIAGNOSTICS – ENGINE INSPECTION PROCEDURE HINT:
If the vehicle run out of fuel, the air–fuel ratio is LEAN and DTC P0125 will be recorded . The MIL then comes on. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc at the time of the malfunction. There is a possibility that P0125 is detected because of abnormal fuel system, so, when P0125 is memorized, check P0171 and P0172 even if P0171 and P0172 are memorized.

1 Are there any other codes (besides DTC P0125) being output ? YES Go to relevant DTC chart. NO 2 Connect the OBD II scan tool or TOYOTA hand–held tester and read value for voltage output of oxygen sensor (bank 1 sensor 1). PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Warm up engine to normal operating temp (above 75°C). CHECK: Read voltage output of the oxygen sensor (bank 1 sensor 1) when engine is suddenly raced. HINT: Perform quick racing to 4,000 rpm 3 times using accelerator pedal. OK: Both oxygen sensor (bank 1 sensor 1) output a RICH signal (0.45 V or more) at least once. OK Go to step 9. NG 3 Check for open and short in harness and connector between ECM and oxygen sensor (bank 1 sensor 1) (See page IN–41). NG OK 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–47 DIAGNOSTICS 4 – ENGINE Check whether misfire is occurred or not by monitoring DTC and data list. NG Perform troubleshooting for misfire (See page DI–65). OK 5 Check air induction system (See page SF–1). NG Repair or replace induction system. OK 6 Check fuel pressure (See page SF–6). NG Check and repair fuel pump and fuel pipe line (See page SF–1). OK 7 Check injector injection (See page SF–12). NG Replace injector. OK 8 Check gas leakade on exhaust system. NG OK 2001 PRIUS (RM778U) Repair or replace. DI–48 DIAGNOSTICS – ENGINE Replace oxygen sensor (bank 1 sensor 1). 9 Perform confirmation driving pattern (See page DI–50). Go 10 Is there DTC P0125 being output again? YES Check and replace ECM. NO 11 Did vehicle runs out of fuel in the past? NO YES DTC P0125 is caused by running out of fuel. 2001 PRIUS (RM778U) Check for intermittent problems (See page DI–3). DI–50 DIAGNOSTICS – ENGINE DI6V3–02 DTC P0130 Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 1) CIRCUIT DESCRIPTION Refer to DTC P0125 on page DI–44. DTC No. P0130 DTC Detecting Condition Trouble Area Voltage output of oxygen sensor remains at 0.42 V or more, or 0.48 V or less, during idling after the engine is warmed up (2 trip detection logic)
Open or short in heated oxygen sensor circuit
Heated oxygen sensor
Air induction system
Fuel pressure
Injector
ECM HINT: Sensor 1 refers to the sensor closer to the engine body. The oxygen sensor’s output voltage and the short−term fuel trim value can be read using the OBD II scan tool or TOYOTA hand−held tester. WIRING DIAGRAM Refer to DTC P0125 on page DI–44. CONFIRMATION DRIVING PATTERN Vehicle speed (d) Constant speed Start online IG SW OFF (c) (a)(b) 30 sec. 36 sec. Time FI7130 A14461 (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Switch the TOYOTA hand–held tester from normal mode to check mode (See page DI–3). (c) Start the engine and pass for 30 sec. or more. (d) Drive the vehicle at constant speed for 36 sec. or more. HINT: If a malfunction exists, the MIL will light up during step (d). NOTICE: If the conditions in this test are not strictly followed, detection of the malfunction will not be possible. If you do not have a TOYOTA hand–held tester, turn the ignition switch OFF after performing steps (c) to (d), then perform steps (c) to (d) again. 2001 PRIUS (RM778U) DI–51 DIAGNOSTICS – ENGINE INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Are there any other codes (besides DTC P0130) being output? YES Go to relevant DTC chart. NO 2 Check the output voltage of oxygen sensor during idling. PREPARATION: Warm up the oxygen sensor the engine at 2,500 rpm for approx. 90 sec. CHECK: Use the OBD II scan tool or TOYOTA hand–held tester read the output voltage of the oxygen sensor during idling. OK: Oxygen sensor output voltage: Alternates repeatedly between less than 0.42 V and more than 0.48 V (See the Following table). 0.48 V 0.42 V P18349 OK NG 2001 PRIUS (RM778U) Go to step 7. DI–52 DIAGNOSTICS 3 – ENGINE Check for open and short in harness and connector between ECM and oxygen sensor (bank 1 sensor 1) (See page IN–30). NG Repair or replace harness or connector. OK 4 Check air induction system (See page SF–1). NG Repair or replace induction system. OK 5 Check fuel pressure (See page SF–6). NG Check and repair fuel pump, fuel pipe line and filter (See page SF–1). OK 6 Check injector injection (See page SF–12). NG Replace injector. OK Replace oxygen sensor (bank 1 sensor 1). 7 Perform confirmation driving pattern (See page DI–50). Go 2001 PRIUS (RM778U) DI–53 DIAGNOSTICS 8 – ENGINE Are there DTC P0130 being output again? YES NO Check and replace ECM. 2001 PRIUS (RM778U) Check for intermittent problems (See page DI–3). DI–54 DIAGNOSTICS – ENGINE DI6V4–02 DTC P0133 Oxygen Sensor Circuit Slow Responce (Bank 1 Sensor 1) CIRCUIT DESCRIPTION Refer to DTC P0125 on page DI–44. DTC No. DTC Detecting Condition Trouble Area P0133 Response time for the oxygen sensor’s voltage output tochange from rich to lean, or from lean to rich, is 0.4 sec. or more during constant vehicle speed after the engine is warmed up (2 trip detection logic)
Open or short in heated oxygen sensor circuit
Heated oxygen sensor
Air induction system
Fuel pressure
Injector
ECM HINT: Sensor 1 refers to the sensor closer to the engine body. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scantool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Are there any other codes (besides DTC P0133) being output? YES NO 2001 PRIUS (RM778U) Go to relevant DTC chart. DI–55 DIAGNOSTICS 2 – ENGINE Check the output voltage of heated oxygen sensor during idling. PREPARATION: Warm up the heated oxygen sensor the engine at 2,500 rpm for approx. 90 sec. CHECK: Use the OBD II scan tool or TOYOTA hand–held tester read the output voltage of the heated oxygen sensor during idling. OK: Oxygen sensor output voltage: Alternates repeatedly between less than 0.42 V and more than 0.48 V (See the Following table). 0.48 V 0.42 V P18349 OK Go to step 7. NG 3 Check for open and short in harness and connector between ECM and heated oxygen sensor (bank 1 sensor 1) (See page IN–30). NG Repair or replace harness or connector. OK 4 Check air induction system (See page SF–1). NG OK 2001 PRIUS (RM778U) Repair or replace induction system. DI–56 DIAGNOSTICS 5 – ENGINE Check fuel pressure (See page SF–6). NG Check and repair fuel pump and fuel pipe line (See page SF–1). OK 6 Check injector injection (See page SF–12). NG Replace injector. OK Replace oxygen sensor (bank 1 sensor 1). 7 Perform confirmation driving pattern (See page DI–50). Go 8 Are there DTC P0133 being output again? YES NO Check and replace ECM. 2001 PRIUS (RM778U) Check for intermittent problems (See page DI–3). DI–57 DIAGNOSTICS – ENGINE DI6V5–02 DTC P0135 Heated Oxygen Sensor Heater Circuit Malfunction (Bank1 Sensor1) DTC P0141 Heated Oxygen Sensor Heated Circuit Malfunction (Bank1 Sensor2) CIRCUIT DESCRIPTION Refer to DTC P0125 on page DI–44. DTC No. P0135 P0141 DTC Detecting Condition When the heater operates, heater current exceeds 2 A (2 trip detection logic) Heater current of 0.2 A or less when the heater operates (2 trip detection logic) Trouble Area
Open or short in heater circuit of heated oxygen sensor
Heated H t d oxygen sensor heater h t
ECM HINT:


Bank 1 refers to the bank that includes cylinder No.1. Sensor 1 refers to the sensor closer to the engine body. Sensor 2 refers to the sensor farther away from the engine body. WIRING DIAGRAM Refer to DTC P0125 on page DI–44. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 2001 PRIUS (RM778U) DI–58 DIAGNOSTICS 1 – ENGINE Check voltage between terminals HT1A, HT1B of ECM connectors and body ground. ON HT1A HT1B (+) (–) A13626 PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals HT1A, HT1B of ECM connectors and body ground. HINT:
Connect terminal HT1A to bank 1 sensor 1.
Connect terminal HT1B to bank 1 sensor 2. OK: Voltage: 9 – 14 V OK Check and replace ECM (See page IN–41). NG 2 Check resistance of heated oxygen sensor heater (See page SF–58). NG Replace heated oxygen sensor. OK Check and repair harness or connector between EFI relay (Marking: EFI), heated oxygen sensor and ECM (See page IN–41). 2001 PRIUS (RM778U) DI–59 DIAGNOSTICS – ENGINE DI6V6–02 DTC P0136 Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) CIRCUIT DESCRIPTION Refer to DTC P0125 on page DI–44. DTC No. DTC Detecting Condition Trouble Area P0136 Voltage output of the heated oxygen sensor remains at 0.45 V or more, or 0.55 V or less when the vehicle is driven at 40 km/h (25 mph) or more after the engine is warmed up. (2 trip detection logic).
Open or short in heated oxygen sensor circuit
Heated oxygen sensor HINT: Sensor 2 refers to the sensor farther away from the engine body. WIRING DIAGRAM Refer to DTC P0125 on page DI–44. CONFIRMATION DRIVING PATTERN Vehicle speed 40 km/h (25 mph) Idling(c) IG SW OFF (a) (b) 60 sec. or more Once 40 sec. or more Twice 40 sec. or more 11 times 40 sec. or more (d) (d) (d) (e) (e) (e) 10 sec. 10 sec. 10 sec. A09300 (a) Connect the hand–held tester to the DLC3. (b) Switch the hand–held tester from the Normal Mode to the Check (Test) Mode (See page DI–3). (c) Start the engine and let the engine idle for 60 seconds or more. (d) Drive the vehicle at 40 km/h (25 mph) or more for 40 seconds or more. (e) Let the engine idle for 10 seconds or more. (f) Preform steps (d) to (e) 11 times. HINT:
During performing the steps (d) to (e) 11 times, drive the vehicle at over 65 km and make the fuel cut happen for over 3 sec.
If a malfunction exists, the MIL will be indicated on the multi information display during step (f). NOTICE: If the conditions in this test are not strictly followed, detection of the malfunction will not be possible. If you do not have a hand–held tester, turn the ignition switch OFF after performing steps (c) to (f), then perform steps (c) to (f) again. 2001 PRIUS (RM778U) DI–60 DIAGNOSTICS – ENGINE INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Are there any other codes (besides DTC P0136) being output? YES Go to relevant DTC chart. NO 2 Check for open and short in harness and connector between ECM and oxygen sensor (See page IN–41). NG Repair or replace harness or connector. OK 3 Check output voltage of oxygen sensor. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Warm up the engine to normal operating temp. CHECK: Read voltage output of oxygen sensor when engine suddenly raced. HINT: Perform a quick racing of 2,000 rpm or more 3 times by using the accelerator pedal. OK: Oxygen sensor output voltage: Alternates from 0.40 V or less to 0.50 V or more. OK NG Replace oxygen sensor. 2001 PRIUS (RM778U) Check that each connector is properly connected. DI–61 DIAGNOSTICS – ENGINE DI6V7–02 DTC P0171 System too Lean (Fuel Trim) DTC P0172 System too Rich (Fuel Trim) CIRCUIT DESCRIPTION Fuel trim refers to the feedback compensation value compared against the basic injection time. Fuel trim includes short–term fuel trim and long–term fuel trim. Short–term fuel trim is the short–term fuel compensation used to maintain the air–fuel ratio at its ideal theoretical value. The signal from the oxygen sensor indicates whether the air–fuel ratio is RICH or LEAN compared to the ideal theoretical value, triggering a reduction in fuel volume if the air–fuel ratio is rich, and an increase in fuel volume if it is lean. Long–term fuel trim is overall fuel compensation carried out long–term to compensate for continual deviation of the short–term fuel trim from the central value due to individual engine differences, wear over time and changes in the usage environment. If both the short–term fuel trim and long–term fuel trim are LEAN or RICH beyond a certain value, it is detected as a malfunction and the MIL lights up. DTC No. P0171 P0172 DTC Detecting Condition Trouble Area When the air–fuel ratio feedback is stable after engine warming up, the fuel trim is considerably in error on the RICH side (2 trip detection logic)
Air induction system
Injector blockage
Mass air flow meter
Engine coolant temp. sensor
Fuel pressure
Gas leakage on exhaust system
Open or short in heated oxygen sensor (bank 1 sensor 1) circuit
Heated oxygen sensor (bank 1 sensor 1) When air fuel ratio feedback is stable after warming up engine, the fuel trim is considerably in error on LEAN side (2 trip detection logic)
Injector leak, blockage
Mass air flow meter
Engine coolant temp. sensor
Ignition system
Fuel pressure
Gas leakage on exhaust system
Open or short in heated oxygen sensor (bank 1, 2 sensor 1) circuit
Heated oxygen sensor (bank 1, 2 sensor 1)
ECM HINT:



When DTC P0171 is recorded, the actual air–fuel ratio is on the LEAN side. When DTC P0172 is recorded, the actual air–fuel ratio is on the RICH side. If the vehicle runs out of fuel, the air–fuel ratio is LEAN and DTC P0171 is recorded. The MIL then comes on. If the total of the short–term fuel trim value and long–term fuel trim value is within ± 38 %, the system is functioning normally. The oxygen sensor output voltage and the short–term fuel trim value can be read using the OBD II scan tool or TOYOTA hand–held tester. 2001 PRIUS (RM778U) DI–62 DIAGNOSTICS – ENGINE INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Check air induction system (See page SF–1). NG Repair or replace. OK 2 Check injector injection (See page SF–12). NG Replace injector. OK 3 Check mass air flow meter and engine coolant temp. sensor (See page SF–22 and SF–49). NG Repair or replace. OK 4 Check for spark and ignition (See page IG–1). NG OK 2001 PRIUS (RM778U) Repair or replace. DI–63 DIAGNOSTICS 5 – ENGINE Check fuel pressure (See page SF–6). NG Check and repair fuel pump and fuel pipe line. OK 6 Check gas leakade on exhaust system. NG Repair or replace. OK 7 Check the output voltage of heated oxygen sensor during idling. PREPARATION: Warm up the oxygen sensor the engine at 2,500 rpm for approx. 90 sec. CHECK: Use the OBD II scan tool or TOYOTA hand–held tester read the output voltage of the heated oxygen sensor during idling. OK: Oxygen sensor output voltage: Alternates repeatedly between less than 0.4 V and more than 0.55 V (See the following table). P18349 OK NG 2001 PRIUS (RM778U) Go to step 9. DI–64 DIAGNOSTICS 8 – ENGINE Check for open and short in harness and connector between ECM and heated oxygen sensor (See page IN–30). NG Repair or replace harness or connector. OK Replace heated oxygen sensor. 9 Perform confirmation driving pattern (See page DI–50). GO 10 Is there DTC P0171 being output again? YES Check and replace ECM. NO 11 Did vehicle runs out of fuel in the past? NO YES DTC P0171 or P0172 is caused by running out of fuel. 2001 PRIUS (RM778U) Check for intermittent problems. DI–65 DIAGNOSTICS – ENGINE DI6V8–03 DTC P0300 Random/Multiple Cylinder Misfire Detected DTC P0301 Cylinder 1 Misfire Detected DTC P0302 Cylinder 2 Misfire Detected DTC P0303 Cylinder 3 Misfire Detected DTC P0304 Cylinder 4 Misfire Detected CIRCUIT DESCRIPTION Misfire: The ECM uses the crankshaft position sensor and camshaft position sensor to monitor changes in the crankshaft rotation for each cylinder. The ECM counts the number of times the engine speed change rate indicates that misfire has occurred. And when the misfire rate equals or exceeds the count indicating that the engine condition has deteriorated, the MIL lights up. If the misfire rate is high enough and the driving conditions will cause catalyst overheating, the MIL blinks when misfiring occurs. DTC No. P0300 P0301 P0302 P0303 P0304 DTC Detecting Condition Misfiring Mi fi i off random d cylinders li d is i detected d t t d during d i any particular ti l 200 or 1,000 revolutions For any particular 200 revolutions for the engine, misfiring is detected which can cause catalyst overheating (This causes MIL to blink) Trouble Area
Open or short in engine wire
Connector connection
Vacuum hose connection
Ignition system
Injector
Fuel pressure
Manifold absolute pressure sensor
Engine coolant temp. tem . sensor
Compression pressure
Valve clearance
Valve timing
ECM HINT:

When the 2 or more codes for a misfiring cylinder are recorded repeatedly but no random misfire code is recorded, it indicates that the misfires were detected and recorded at different times. There is a case where the cylinder other than memorized has an accidental fire (the cylinder which is one ahead of fired cylinder), so. at the time of checking all the checking items and if there is no abnormality, check the cylinder which is different from the recorded cylinder as fired. 2001 PRIUS (RM778U) DI–66 DIAGNOSTICS – ENGINE WIRING DIAGRAM B–W B–W Engine RoomJ/B 2 1A 3 1K 3 9 1J 3 1J 5 2 1 IG2 Relay B–W W–R B–W Instrument Panel J/B 2G 11 1 2G 2B 5 J7 J/C B A W–B 2 2C 1 5 E8 #10 B–R 6 E8 #20 L–W 1 E7 #30 2 I7 Injector No. 3 1 B–W Y 2 B–W B–W W–B A B–W Engine ECU I6 Injector No. 2 B–W AM2 1B 2 1 I5 Injector No. 1 2 I8 Injector No. 4 R–W 1 W–R I15 Ignition SW 6 IG2 AM2 7 FL Block No. 1 F18 FL Block No. 2 1 1 MAIN B–G F12 F13 1 2 2 E7 #40 B–W A J1 J/C 1E Battery A14053 CONFIRMATION DRIVING PATTERN (a) (b) (c) (d) Connect the TOYOTA hand–held tester or OBD II scan tool. Record DTC and the freeze frame data. Use the TOYOTA hand–held tester to set to Check Mode. (See page DI–3) Drive the vehicle several times with the engine speed, load and its surrounding range shown with ENGINE SPD, CALC LOAD in the freeze frame data or MISFIRE RPM, MISFIRE LOAD in the data list. If you have no TOYOTA hand–held tester, turn the ignition switch OFF after the symptom is simulated the first time. Then repeat the simulation process again. HINT: In order to memorize DTC of misfire, it is necessary to drive around MISFIRE RPM, MISFIRE LOAD in the data list for the following period of time. (e) Engine Speed Time 1000 rpm 3 minutes or more 2000 rpm 1 minute 30 seconds or more 3000 rpm 1 minute or more Check whether there is misfire or not by monitoring DTC and the freeze frame data. After that, record them. 2001 PRIUS (RM778U) DI–67 DIAGNOSTICS (f) – ENGINE Turn ignition switch OFF and wait at least 5 seconds. INSPECTION PROCEDURE HINT:
If is the case that DTC besides misfire is memorized simultaneously, first perform the troubleshooting for them. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame data records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. When the vehicle is brought to the workshop and the misfire is not occurred, misfire can be confirmed by reproducing the condition or freeze frame data. Also, after finishing the repair, confirm that there is no misfire. (See the confirmation driving pattern) When either of SHORT FT #1, LONG FT #1, SHORT FT #2 or LONG FT #2 in the freeze frame data is besides the range of ±20%, there is a possibility that the air–fuel ratio is inclining either to ”rich” (–20% or less) or ”lean” (+20% or more). When COOLANT TEMP in the freeze frame data is less than 80°C (176°F), there is a possibility or misfire only during warming up. In the case that misfire cannot be reproduced, the reason may be because of the driving with lack or fuel, the use of improper fuel, a stain of ignition plug, and etc.




1 Check wire harness, connector and vacuum hose in engine room. CHECK: (a) Check the connection conditions of wire harness and connector. (b) Check the disconnection, piping and break of vacuum hose. NG Repair or replace, then confirm that there is no misfire. (See the confirmation driving pattern) OK 2 Check spark plug and spark of misfiring cylinder. P03792 2001 PRIUS (RM778U) PREPARATION: Remove the spark plug (See page IG–1). CHECK: (a) Check for carbon deposits on electrode. (b) Check electrode gap. OK: (a) No large carbon deposit present. Not wet with gasoline or oil. (b) Electrode gap: 1.0 – 1.2 mm (0.039 – 0.047 in.) PREPARATION: (a) Install the spark plug to ignition coil and connect the ignition coil connector to ignition coil. DI–68 DIAGNOSTICS – ENGINE (b) Disconnect the injector connector. (c) Ground spark plug. CHECK: Check if spark occurs while engine is being cracked. NOTICE: To prevent excess fuel being injected from the injectors during this test, don’t crank the engine for more than 5 – 10 seconds at a time. OK: Spark jumps across electrode gap. NG Replace or check ignition system (See page IG–1). OK 3 Check voltage of ECM terminal for injector of failed cylinder. ON #40 #30 #20 #10 (+) (–) A13627 PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Turn the ignition switch ON. CHECK: Measure voltage between applicable terminal of the ECM connector and body ground. OK: Voltage: 9 – 14 V Reference: INSPECTION USING OSCILLOSCOPE INJECTOR SIGNAL WAVEFORM With the engine idling, measure between terminals #10 ∼ #40 and E01 of the ECM connector. HINT: The correct waveforms are shown. Injector Signal Waveform (Magnification) 10V/ Division 10V/ Division GND GND 100 m sec./Division (Idling) FI6588 FI6538 Injection duration 1 m sec./Division (Idling) A00064 2001 PRIUS (RM778U) DI–69 DIAGNOSTICS – OK ENGINE Go to step 5. NG 4 Check resistance of injector of misfiring cylinder (See page SF–9). NG Replace injector. OK Check for open and short in harness and connector between injector and ECM (See page IN–41). 5 Check fuel pressure (See page SF–6). NG Check and repair fuel pump and fuel pipe line (See page SF–1). OK 6 Check injector injection (See page SF–12). NG Replace injector. OK 7 Check mass air flow merer and engine coolant temp. sensor (See page SF–22 and SF–49). NG 2001 PRIUS (RM778U) Repair or replace. DI–70 DIAGNOSTICS OK Check compression pressure, valve clearance and valve timing (See page EM–3, EM–5, EM–21). 2001 PRIUS (RM778U) – ENGINE DI–71 DIAGNOSTICS – ENGINE DI6V9–02 DTC P0325 Knock Sensor 1 Circuit Malfunction CIRCUIT DESCRIPTION The knock sensor is fitted to the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. DTC No. P0325 DTC Detecting Condition Trouble Area
Open or short in knock sensor 1 circuit
Knock sensor 1 (looseness)
ECM No knock sensor 1 signal to ECM with engine speed, 2,000 rpm or more HINT: If the ECM detects above diagnosis conditions, it operates the fail safe function in which the corrective retard angle value is set to the maximum value. WIRING DIAGRAM Knock Sensor 1 (Shielded) B 1 EA1 A J9 BR J/C A J8 ECM 28 E7 KNK1 BR EB A14027 2001 PRIUS (RM778U) DI–72 DIAGNOSTICS – ENGINE INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Check continuity between terminal KNK1 of ECM connector and body ground. LOCK E7 Connector KNK1 A13628 PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Disconnect the E7 connector of the ECM. CHECK: Measure resistance between terminal KNK1 of the ECM connector and body ground. OK: Resistance: 1 MΩ or higher OK Go to step 3. NG 2 Check knock sensor (See page SF–56). NG Replace knock sensor. OK 3 Check for open and short in harness and connector between ECM and knock sensor (See page IN–41). NG OK 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–73 DIAGNOSTICS 4 – ENGINE Does malfunction disappear when a good knock sensor is installed? YES Replace knock sensor. NO Check and replace ECM (See page IN–41). Reference: INSPECTION USING OSCILLOSCOPE
With the engine racing (4,000 rpm) measure between terminal KNK of the ECM connector and body ground. HINT: The correct waveforms are as shown. KNK signal waveform 0.5V/ Division 0V 5 m sec./Division 0.5V/ Division
0V 100 sec./Division A00406 2001 PRIUS (RM778U) Spread the time on the horizontal axis, and confirm that period of the wave is 132 µ sec. (Normal mode vibration frequency of knock sensor: 8.1 kHz) HINT: If normal mode vibration frequency is not 8.1 kHz the sensor is malfunctioning. DI–74 DIAGNOSTICS – ENGINE DI6VA–02 DTC P0335 Crankshaft Position Sensor ”A” Circuit Malfunction CIRCUIT DESCRIPTION Crankshaft position sensor (NE signal) consist of a signal plate and pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals of every engine revolution. The ECM detects the standard crankshaft angle based on the G2 signals, and the actual crankshaft angle the engine speed by the NE signals. DTC No. DTC Detecting Condition Trouble Area No crankshaft position sensor signal to ECM during cranking. (2 trip detection logic) P0335 No crankshaft position sensor signal to ECM with engine speed 600 rpm or more (2 trip detection logic)
Open or short in crankshaft position sensor circuit.
Crankshaft position osition sensor
Signal plate (Timing belt guide)
Crankshaft timing pulley
ECM WIRING DIAGRAM (Shielded) ECM 10 E7 G2 R C1 1 Camshaft Position Sensor 2 G (Shielded) G C6 2 Crankshaft Position Sensor 1 G 16 E8 NE+ R BR BR BR 24 E8 NE– A J8 J/C A J8 BR A J9 EB A14028 2001 PRIUS (RM778U) DI–75 DIAGNOSTICS – ENGINE INSPECTION PROCEDURE HINT:
Perform troubleshooting of DTC 335 1st. If notrouble is found, troubleshoot the following mechanical system. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction.
1 Check resistance of crankshaft position sensor (See page IG–1). G2, NE signal waveforms 5V/ Division G2 Reference: INSPECTION USING OSCILLOSCOPE During cranking or idling, check between terminals G2 and NE–, NE and NE– of the ECM HINT: The correct waveforms are as shown. NE NG 20 m sec./Division (Idling) Replace crankshaft position sensor. A14463 OK 2 Check for open and short in harness and connector between ECM and crankshaft position sensor (See page IN–41). NG Repair or replace harness or connector. OK 3 Inspect crankshaft position sensor installation and teeth of crankshaft timing pulley (See page IG–11 and EM–13). NG OK Check and replace ECM (See page IN–41). 2001 PRIUS (RM778U) Tighten the sensor. Replace crankshaft timing pulley. DI–76 DIAGNOSTICS – ENGINE DI6VB–02 DTC P0340 Camshaft Position Sensor Circuit Malfunction CIRCUIT DESCRIPTION Camshaft position sensor (G22 signal) consist of signal plate and pick up coil. The G22 signal plate has one tooth on its outer circumference and is mounted on the exhaust camshaft. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pick up coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G22 signals and the actual crankshaft angle and the engine speed by the NE signals. DTC No. DTC Detecting Condition Trouble Area No camshaft position sensor signal to ECM during cranking. (2 trip detection logic) P0340 No camshaft position sensor signal to ECM with engine speed 600 rpm or more
Open or short in camshaft position sensor circuit
Camshaft position osition sensor
Camshaft timing pulley
ECM WIRING DIAGRAM Refer to DTC P0335 on page DI–74. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Check resistance of camshaft position sensor (Signal generator) (See page IG–1). Reference: INSPECTION USING OSCILLOSCOPE Refer to DTC P0335 on page DI–74 for the INSPECTION USING OSCILLOSCOPE. NG OK 2001 PRIUS (RM778U) Replace camshaft position sensor. DI–77 DIAGNOSTICS 2 – ENGINE Check for open and short in harness and connector between ECM and camshaft position sensor (See page IN–41). NG Repair or replace harness or connector. OK 3 Inspect sensor installation and tooth of camshaft timing pulley (See page EM–15). NG OK Check and replace ECM (See page IN–41). 2001 PRIUS (RM778U) Tighten the sensor. Replace camshaft timing pulley. DI–78 DIAGNOSTICS – ENGINE DI6VC–02 DTC P0420 Catalyst System Efficiency Below Threshold CIRCUIT DESCRIPTION The ECM compares the waveform of the oxygen sensor located before the catalyst with the waveform of the oxygen sensor located behind the catalyst to determine whether or not catalyst performance has deteriorated. Air–fuel ratio feedback compensation keeps the waveform of the oxygen sensor before the catalyst repeatedly changing back and forth from rich to lean. If the catalyst is functioning normally, the waveform of the oxygen sensor behind the catalyst switches back and forth between rich and lean much more slowly than the waveform of the oxygen sensor before the catalyst. But when both waveforms change at a similar rate, it indicates that catalyst performance has deteriorated. Waveform of Heated Oxygen Sensor before Catalyst Normal Catalyst Waveform of Heated Oxygen Sensor behind Catalyst FI7081 DTC No. DTC Detecting Condition Trouble Area P0420 After the engine and the catalyst are warmed up, and while the vehicle is driven within the set vehicle and engine speed range, the waveforms of the oxygen sensors (bank 1 sensor 1 and bank 1 sensor 2) have the same amplitude (2 times detection logic)
Gas leakage on exhaust system
Open or short in heated oxygen sensor circuit
Heated oxygen sensor
Three–way catalytic converter CONFIRMATION DRIVING PATTERN Vehicle Speed (c) 89 km/h (55 mph) (d) Idling (b) 0 IG SW OFF (a) (b) (a) Warmed up Warmed up 5 min. or more Check Time FI7132 Connect the TOYOTA hand–held tester to the DLC3, or connect the probe of the oscilloscope between terminals OX1, OX2 and E1 of the ECM connector. Start engine and warm it up with all accessories switched OFF until water temp. is stable. 2001 PRIUS (RM778U) DI–79 DIAGNOSTICS (c) (d) – ENGINE Drive the vehicle at 89 km/h (55 mph) or more for 5 min. or more. After confirming that the waveforms of the oxygen sensor, bank 1 sensor 1 (OX1), oscillate around 0.5 V during feedback to the ECM, check the waveform of the oxygen sensor, bank 1 sensor 2 (OX2). HINT: OX Signal Waveform (Oscilloscope)
If there is a malfunction in the system, the waveform of the 1.0 V oxygen sensor, bank 1 sensor 2 (OX2),is shown on the 0.5 V OX1 left.
There are some cases where, even though a malfunction 0V 1.0 V exists, the MIL may either light up or not light up. OX2
Normal waveform of OX2 is a smooth line of 0.6 to 0.7 V. 0.5 V 0V 500 msec./Division A14462 INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Are there any other codes (besides DTC P0420) being output? YES Go to relevant DTC chart. NO 2 Check gas leakage on exhaust system. NG Repair or replace. OK 3 Check for open and short in harness and connector between heated oxygen sensor (bank 1 sensor 1, 2) and ECM. NG OK 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–80 DIAGNOSTICS 4 – ENGINE Check oxygen sensor (bank 1 sensor 1) (See page DI–50). NG Repair or replace. OK 5 Check oxygen sensor (bank 1 sensor 2) (See page DI–59). NG OK Replace three–way catalytic converter. 2001 PRIUS (RM778U) Repair or replace. DI–81 DIAGNOSTICS – ENGINE DI7ST–01 DTC P0440 Evaporative Emission Control System Malfunction CIRCUIT DESCRIPTION The vapor pressure sensor, VSV for canister closed valve (CCV) and VSV for purge flow switching valve are used to detect abnormalities in the evaporative emission control system. The ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal. DTC P0440 is recorded by the ECM when evaporative emissions leak from the components or when the vapor pressure sensor malfunctions. Fig. 1 (9) VSV for EVAP (8) ECM VSV for Purge Flow switching Valve Charcoal Canister (2) (7) (3) (5) Fresh Air (6) Valve VSV for Vapor Pressure Sensor CCV (1) (4) Fuel Tank A14039 DTC No. P0440 DTC Detecting Condition When the vacuum applied to the sealed tank cannot be kept for a fixed time. 2001 PRIUS (RM778U) Trouble Area
Hose or tube cracked, hole, damaged or loose seal ((3) and (4) in Fig. 1)
Fuel tank cap incorrectly installed
Fuel tank cap cracked or damaged
Vacuum hose cracked, holed, blocked, damaged or disconnected ((1) (2) and (3) in Fig. 1)
Fuel tank cracked, holed or damaged
Charcoal canister cracked, holed or damaged
Open or short in vapor pressure sensor circuit
Vapor pressure sensor
ECM DI–82 DIAGNOSTICS – ENGINE WIRING DIAGRAM Engine Room J/B 1 EFI Relay 5 12 6 1F 2 3 1K 3 3 1A B 2 1B 2 A J5 B A J5 A J7 J/C A B–G 25 E9 ECM MREL 29 E7 EVP1 19 IA1 B B 1 J/C A J5 B C J4 B B W–B A J1 J/C Battery J/C R–L 1 W–B FL Block No. 1 1 1 F12 F13 F18 MAIN FL Block No. 2 C J4 G–R V2 VSV (EVAP) B 13 1F EFI 4 IA2 G–R IE V5 VSV (Purge Flow Switching Valve) 2 5 B B–R B–R BC1 BC1 2 1 V6 VSV (Canister Closed Valve) 1 6 L L B BC1 BC1 2 1 V4 Vapor Pressure Sensor 15 IO1 Y–R 3 BC1 Y–R 4 BR 1 BC1 L–R 2 BC1 7 J8 J/C Y–R C C Y–R 11 E9 TBP 13 E9 CCV BR 18 E8 E2 L–R 22 E9 PTNK 2 E8 VC A14054 INSPECTION PROCEDURE HINT:


If DTC P0441, P0446, P0450 or P0451 is output after DTC P0440, first troubleshoot DTC P0441, P0446, P0450 or P0451. If no malfunction is detected, troubleshoot DTC P0440 next. Ask the customer whether, after the MIL came on, the customer found the fuel tank cap loose and tightened it. Also ask the customer whether the fuel tank cap was loose when refuelling. If the fuel tank cap was loose, it was the cause of the DTC. If the fuel tank cap was not loose or if the customer was not sure if it was loose, troubleshoot according to the following procedure. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting, it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction. 2001 PRIUS (RM778U) DI–83 DIAGNOSTICS
– ENGINE When the ENGINE RUN TIME in the freeze frame data is less than 200 seconds, carefully check the VSV for EVAP, charcoal canister and vapor pressure sensor. 1 Check whether hose close to fuel tank have been modified, and check whether there are signs of any accident near fuel tank or charcoal canister. CHECK: Check for cracks, deformation and loose connection of the following parts:
Fuel tank
Charcoal canister
Fuel tank filler pipe
Hoses and tubes around fuel tank and charcoal canister NG Repair or replace. OK 2 Check that fuel tank cap is TOYOTA genuine parts. NG Replace to TOYOTA genuine parts. OK 3 Check that fuel tank cap is correctly installed. NG Correctly install fuel tank cap. OK 4 Check fuel tank cap (See page EC–7). NG OK 2001 PRIUS (RM778U) Replace fuel tank cap. DI–84 DIAGNOSTICS 5 – ENGINE Check filler neck for damage. PREPARATION: Remove the fuel tank cap. CHECK: Visually inspect the filler neck for damage. NG Replace filler pipe. OK 6 Check vacuum hoses ((1), (2) and (3) in Fig. 1 in circuit description). CHECK: (a) Check that the vacuum hose is connected correctly. (b) Check the vacuum hose for looseness and disconnection. (c) Check the vacuum hose for cracks, hole and damage. NG Repair or replace. OK 7 Check hose and tube around fuel tank and charcoal canister. CHECK: (a) Check for proper connection ((4), (5), (6) and (7) in Fig. 1 in circuit description). (b) Check the hose and tube for cracks, hole and damage. NG Repair or replace. OK 8 Check charcoal canister for cracks, hole and damage (See page EC–7). NG OK 2001 PRIUS (RM778U) Replace charcoal canister. DI–85 DIAGNOSTICS 9 – ENGINE Check voltage between terminals VC and E2 of ECM connector. ON VC (+) E2 (–) A13624 CHECK: (a) Remove the ECM with connector still connected (See page SF–62). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals VC and E2 of the ECM connector. OK: Voltage: 4.5 – 5.5 V NG Check and replace ECM (See page IN–41). OK 10 Check voltage between terminals PTNK and E2 of ECM connectors. ON E2 (–) PTNK (+) A14040 PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Remove the fuel tank cap. (c) Turn the ignition switch ON. CHECK: Measure the voltage between terminals PTNK and E2 of the ECM connectors. OK: Voltage: 3.0 – 3.6 V OK Go to step 12. NG 11 Check for open and short in harness and connector between vapor pressure sensor and ECM (See page IN–41). NG OK 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–86 DIAGNOSTICS – ENGINE Replace vapor pressure sensor. 12 Check fuel tank and fuel tank over fill check valve for cracks and damage. NG Replace fuel tank or fuel tank over fill check valve. OK It is likely that vehicle user did not properly close fuel tank cap. Please explain to customer how to properly install fuel tank cap. 2001 PRIUS (RM778U) DI–87 DIAGNOSTICS – ENGINE DI7SU–01 DTC P0441 Evaporative Emission Control System Incorrect Purge Flow DTC P0446 Evaporative Emission Control System Vent Control Malfunction CIRCUIT DESCRIPTION The vapor pressure sensor, VSV for canister closed valve (CCV), VSV for purge flow switching valve are used to detect abnormalities in the evaporative emission control system. The ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal. DTCs P0441 and P0446 are recorded by the ECM when evaporative emissions leak from the components. 1 below, or when there is a malfunction in either the VSV for EVAP, the VSV for purge flow switching valve, the VSV for CCV or in the vapor pressure sensor itself. Fig. 1 (9) VSV for EVAP (8) ECM VSV for Purge Flow switching Valve Charcoal Canister (2) (7) (3) (5) Fresh Air (6) Valve VSV for Vapor Pressure Sensor CCV (1) (4) Fuel Tank A14039 2001 PRIUS (RM778U) DI–88 DIAGNOSTICS DTC No. – ENGINE DTC Detecting Condition Trouble Area Pressure in fuel tank does not drop during purge control (2 trip detection logic) P0441 During purge cut–off, pressure in fuel tank is very low compared with atmospheric pressure (2 trip detection logic) When VSV for CCV is ON, ON pressure in fuel tank is maintained at atmospheric h i pressure (2 trip i d detection i llogic) i ) Turning the VSV for purge flow switching valve is ON does not lower the pressure sensor output. P0446 Although the VSV for purge flow switching valve is OFF, fluctuation in the pressure sensor output is great.
Open or short in vapor pressure sensor circuit
Vapor pressure sensor
Open or short in VSV circuit for EVAP
VSV ffor EVAP
O Open en or short in VSV circuit for purge urge flow switching valve
VSV for purge flow switching valve
Charcoal canister cracked, hole or damaged
Open or short in VSV circuit for CCV
VSV for CCV
ECM Turning the VSV for CCV OFF does not charge the pressure sensor output. WIRING DIAGRAM Refer to DTC P0440 on page DI–81. INSPECTION PROCEDURE HINT:
If DTC P0441, P0446, P0450 or P0451 is output after DTC P0440,first troubleshoot DTC P0441, P0446, P0450 or P0451. If no malfunction is detected, troubleshoot DTC P0440 next. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting, it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction. When the ENGINE RUN TIME in the freeze frame data is less than 200 seconds, carefully check the VSV for EVAP, charcoal canister and vapor pressure sensor.

TOYOTA hand–held tester: 1 Check whether hose close to fuel tank have been modified, and check whether there are signs of any accident near fuel tank or charcoal canister (See page DI–81). NG Repair or replace. OK 2 Check that fuel tank cap is TOYOTA genuine parts. NG OK 2001 PRIUS (RM778U) Replace to TOYOTA genuine parts. DI–89 DIAGNOSTICS 3 – ENGINE Check that fuel tank cap is correctly installed. NG Correctly install fuel tank cap. OK 4 Check fuel tank cap (See page EC–7). NG Replace fuel tank cap. NG Replace filler pipe. OK 5 Check filler neck for damage. OK 6 Check vacuum hoses ((1), (2) and (3) in Fig. 1 in circuit description. NG Repair or connect VSV or sensor connector. OK 7 Check hose and tube around fuel tank and charcoal canister (See page DI–81). NG OK 2001 PRIUS (RM778U) Repair or replace. DI–90 DIAGNOSTICS 8 – ENGINE Check VSV connector for EVAP, VSV connector for CCV, VSV connector for purge flow switching valve and vapor pressure sensor connector for looseness and disconnection. NG Repair or connect VSV or sensor connector. OK 9 Check vacuum hoses ((4), (5), (6) and (7) in Fig. 1 in circuit description). CHECK: (a) Check that the vacuum hose is connected correctly. (b) Check the vacuum hose for looseness and disconnection. (c) Check the vacuum hose for cracks, hole, damage and blockage. NG Repair or replace. OK 10 Check voltage between terminals VC and E2 of ECM connector (See page DI–81). NG Check and replace ECM (See page IN–41). OK 11 Check voltage between terminals PTNK and E2 of ECM connectors (See page DI–81). OK NG 2001 PRIUS (RM778U) Go to step 13. DI–91 DIAGNOSTICS 12 – ENGINE Check for open and short in harness and connector between vapor pressure sensor and ECM (See page IN–41). NG Repair or replace harness or connector. OK Replace vapor pressure sensor. 13 Check purge flow. To Throttle Body A14044 PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Select the ACTIVE TEST mode on the TOYOTA hand– held tester. (c) Disconnect the vacuum hose from the VSV for the EVAP from the charcoal canister. (d) Start the engine. CHECK: When the VSV for the EVAP is operated by the TOYOTA hand– held tester, check whether the disconnected hose applies suction to your finger. OK: VSV is ON: Disconnected hose applies suction to your finger. VSV is OFF: Disconnected hose applies no suction to your finger. OK NG 2001 PRIUS (RM778U) Go to step 16. DI–92 DIAGNOSTICS 14 – ENGINE Check vacuum hose between intake manifold and VSV for EVAP, and VSV for EVAP and charcoal canister. CHECK: (a) Check that the vacuum hose is connected correctly. (b) Check the vacuum hose for looseness and disconnection. (c) Check the vacuum hose for cracks, hole, damage and blockage. NG Repair or replace. OK 15 Check operation of VSV for EVAP (See page SF–40). OK Go to step 16. NG Replace VSV and charcoal canister,and then clean the vacuum hose between throttle body and VSV for EVAP, and VSV for EVAP and charcoal canister. 16 Check for open and short in harness and connector between EFI main relay (Marking: EFI) and VSV for EVAP, and VSV for EVAP and ECM (See page IN–41). NG OK Check and replace ECM (See page IN–41). 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–93 DIAGNOSTICS 17 – ENGINE Check VSV for CCV. VSV is ON F F VSV is OFF E E Air Air A14043 PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Remove the VSV for the CCV from the charcoal canister. (c) Turn the ignition switch ON and push the TOYOTA hand– held tester main switch ON. (d) Select the ACTIVE TEST mode on the TOYOTA hand– held tester. CHECK: Check the VSV operation when it is operated by the TOYOTA hand–held tester. OK: VSV is ON: Air does not flow from port E to port F. VSV is OFF: Air from port E flows out through port F. OK Go to step 21. NG 18 Check vacuum hose between VSV for CCV and fresh air valve. CHECK: (a) Check that the vacuum hose is connected correctly. (b) Check the vacuum hose for looseness and disconnection. (c) Check the vacuum hose for cracks, hole damage and blockage. NG Repair or replace. OK 19 Check operation of VSV for CCV. OK NG 2001 PRIUS (RM778U) Go to step 20. DI–94 DIAGNOSTICS – ENGINE Replace VSV and charcoal canister, and then clean vacuum hose between charcoal canister and VSV for CCV. 20 Check for open and short in harness and connector between EFI main relay (Marking: EFI) and VSV for CCV, and VSV for CCV and ECM (See page IN–41). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN–41). 21 Connect TOYOTA hand–held tester and check operation of VSV purge flow switching valve. VSV is ON E VSV is OFF E F F Air Filter Air Filter A14464 PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand– held tester main switch ON. (c) Select the ACTIVE TEST mode on the TOYOTA hand– held tester. CHECK: Check operation of VSV when VSV is operated by the TOYOTA hand–held tester. OK: VSV is ON: Air from pipe E is flowing out through pipe F. VSV is OFF: Air from pipe E is flowing out through the air filter. OK Go to step 24. NG 22 Check VSV for purge flow switching valve (See page SF–45). NG 2001 PRIUS (RM778U) Go to step 23. DI–95 DIAGNOSTICS – ENGINE OK Replace VSV and charcoal canister, and clean vacuum hoses ((1), (2) and (3) in Fig. 1 in circuit description. 23 Check for open and short in harness and connector between EFI main relay (Marking: EFI) and VSV for purge flow switching valve, and VSV for purge flow switching valve and ECU (See page IN–41). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN–41). 24 Check fuel tank and charcoal canister. START VSV for EVAP ON OFF VSV for CCV ON OFF 1.2 V 30 sec. Measure Voltage E2 PTNK (+) BE6653 A10620 A14040 (–) PREPARATION: (a) Remove the connector cover from the ECM. (b) Connect the TOYOTA hand–held tester to the DLC3. (c) Select the ACTIVE TEST mode on the TOYOTA hand– held tester. (d) Start the engine. (e) The VSV for the CCV is ON by the TOYOTA hand–held tester. (f) The VSV for the EVAP is ON by the TOYOTA hand–held tester and hold the VSV for EVAP until voltage between terminals PTNK and E2 becomes 1.2 V, then set VSV for EVAP OFF. CHECK: Measure the voltage between terminals PTNK and E2 of the ECM connectors 30 sec. after switching the VSV for the EVAP from ON to OFF. OK: Voltage: 2.3 V or less A14045 OK NG 2001 PRIUS (RM778U) Check and replace ECM. DI–96 DIAGNOSTICS 25 – ENGINE Remove fuel tank and check it. NG Replace fuel tank. OK 26 Remove charcoal canister and check it (See page EC–7). NG Replace charcoal canister. OK Check and replace ECM (See page IN–41). OBD II scan tool (excluding TOYOTA hand–held tester): 1 Check whether hose close to fuel tank have been modified, and check whether there are signs of any accident near fuel tank or charcoal canister (See page DI–81). NG Repair or replace. OK 2 Check that fuel tank cap is TOYOTA genuine parts. NG Replace to TOYOTA genuine parts. OK 3 Check that fuel tank cap is correctly installed. NG 2001 PRIUS (RM778U) Correctly install fuel tank cap. DI–97 DIAGNOSTICS – ENGINE OK 4 Check fuel tank cap (See page EC–7). NG Replace fuel tank cap. NG Replace filler pipe. OK 5 Check filler neck for damage. OK 6 Check VSV connector for EVAP, VSV connector for CCV, VSV connector for purge flow switching valve and vapor pressure sensor connector for looseness and disconnection. NG Repair or connect VSV or sensor connector. OK 7 Check vacuum hoses ((1), (2) , (3), (4), (5), (6), (7), (8) and (9) in Fig. 1 in circuit description). CHECK: (a) Check that the vacuum hose is connected correctly. (b) Check the vacuum hose for looseness and disconnection. (c) Check the vacuum hose for cracks, hole damage and blockage. NG OK 2001 PRIUS (RM778U) Repair or replace. DI–98 DIAGNOSTICS 8 – ENGINE Check voltage between terminals VC and E2 of ECM connector (See page DI–81). NG Check and replace ECM (See page IN–41). OK 9 Check voltage between terminals PTNK and E2 of ECM connectors (See page DI–81). OK Go to step 11. NG 10 Check for open and short in harness and connector between vapor pressure sensor and ECM (See page IN–41). NG OK Replace vapor pressure sensor. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–99 DIAGNOSTICS 11 – ENGINE Check VSV for EVAP. PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Turn the ignition switch ON. CHECK: Check VSV function. (1) Connect between terminal EVP1 of the ECM connector and body ground (VSV ON). (2) Disconnect between terminal EVP1 of the ECM connector and body ground (VSV OFF). OK: (1) VSV is ON: Air from port E flows out through port F. (2) VSV is OFF: Air does not flow from port E to port F. ON EVP1 VSV is OFF VSV is ON E F E F VSV is ON VSV is OFF OK BE6653 A14041 A12550 Go to step 14. A14046 NG 12 Check operation of VSV for EVAP (See page SF–40). NG Go to step 13. NG Replace VSV and clean vacuum hoses between throttle body and VSV for EVAP, and VSV for EVAP and charcoal canister, and then check charcoal canister. 13 Check for open and short in harness and connector between EFI main relay (Marking: EFI) and VSV for EVAP, and VSV for EVAP and ECM (See page IN–41). NG OK 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–100 DIAGNOSTICS – ENGINE Check and replace ECM (See page IN–41). 14 Check VSV for CCV. PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Turn the ignition switch ON. CHECK: Check the VSV function. (1) Connect between terminal CCV of the ECM connector and body ground (VSV ON). (2) Disconnect between terminal CCV of the ECM connector and body ground (VSV OFF). OK: VSV is ON: Air does not flow from port E to port F. VSV is OFF: Air from port E flows out through port F. ON CCV VSV is OFF VSV is ON F F E Air VSV is ON A14042 A14043 E Air VSV is OFF OK Go to step 17. A14047 NG 15 Check operation of VSV for CCV (See page SF–42). OK Go to step 16. NG Replace VSV and charcoal canister, and then clean vacuum hoses between charcoal canister and VSV for CCV. 16 Check for open and short in harness and connector between EFI main relay (Marking: EFI) and VSV for CCV, and VSV for CCV and ECM (See page IN–41). NG 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–101 DIAGNOSTICS – ENGINE OK Check and replace ECM (See page IN–41). 17 Check VSV for purge flow switching valve. PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Turn the ignition switch ON. CHECK: Check the VSV function. (1) Connect between terminal TBP of the ECM connector and body ground (ON). (2) Disconnect between terminal TBP of the ECM connector and body ground (OFF). OK: (1) VSV is ON: Air from pipe E is flowing out through pipe F. (2) VSV is OFF: Air from pipe E flows out through pipe G. ON TBP VSV is OFF VSV is ON Air Air G F E E OK BE6653 A14048 A14464 VSV is OFF VSV is ON Check and replace charcoal canister (See page EC–7). A14049 NG 18 Check operation of VSV for purge flow switching valve (See page SF–45). OK Go to step 19. NG Replace VSV and charcoal canister, and then clean vacuum hoses ((!), (2) and (3) in Fig. 1 in circuit description). 2001 PRIUS (RM778U) DI–102 DIAGNOSTICS 19 – ENGINE Check for open and short in harness and connector between EFI main relay (Marking: EFI) and VSV for purge flow switching valve, and VSV for purge flow switching valve and ECM (See page IN–41). NG OK Check and replace ECM (See page IN–41). 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–103 DIAGNOSTICS – ENGINE DI7SV–01 DTC P0450 Evaporative Emission Control System Pressure Sensor Malfunction DTC P0451 Evaporative Emission Control System Pressure Sensor Range/Performance CIRCUIT DESCRIPTION The vapor pressure sensor, VSV for canister closed valve (CCV) and VSV for pressure switching valve are used to detect abnormalities in the evaporative emission control system. The ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal. DTC P0450 or P0451 is recorded by the ECM when the vapor pressure sensor malfunction. DTC No. P0450 P0451 DTC Detecting Condition 10 seconds or less after engine starting condition (a) or (b) continues for 7 seconds or more: (2 trip detection logic) (a) Vapor pressure sensor value < –4.0 kPa (–30 mmHg, –1.2 in.Hg) (b) Vapor pressure sensor value
2.0 kPa (15 mmHg, 0.6 in.Hg) Vapor pressure sensor output extremely changes under condition: Vehicle speed: 0 km/h (0mph),Engine speed: Idling (2 trip detection logic) Trouble Area
Open or short in vapor pressure sensor circuit
Vapor pressure sensor
ECM WIRING DIAGRAM Refer to DTC P0440 on page DI–81. INSPECTION PROCEDURE HINT:


If DTC P0441, P0446, P0450 or P0451 is output after DTC P0440, first trouble shoot DTC P0441, P0446 P0450 or P0451. If no malfunction is detected, troubleshoot DTC P0440 next. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting, it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction. When the ENGINE RUN TIME in the freeze frame data is less than 200 seconds, carefully check the VSV for EVAP, charcoal canister and vapor pressure sensor. 2001 PRIUS (RM778U) DI–104 DIAGNOSTICS 1 – ENGINE Check voltage between terminals VC and E2 of ECM connector (See page DI–81). NG Check and replace ECM (See page IN–41). OK 2 Check voltage between terminals PTNK and E2 of ECM connectors (See page DI–81). OK Check and replace ECM (See page IN–41). NG 3 Check for open and short in harness and connector between vapor pressure sensor and ECM (See page IN–41). NG OK Replace vapor pressure sensor. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–105 DIAGNOSTICS – ENGINE DI6VG–02 DTC P0500 Vehicle Speed Sensor Malfunction CIRCUIT DESCRIPTION The speed sensor for ABS detects the wheel speed and sends the appropriate signals to the ABS ECU. The ECU converts these signals into a 4–pulse signal and output it to the combination meter. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The determines the vehicle speed based on the frequency of these pulse signals. 4–Pulse 4–Pulse From Speed Sensor ABS ECU ECM Combination Meter A00022 DTC No. DTC Detecting Condition Trouble Area P0500 During vehicle is being driven, no vehicle speed sensor signal to ECM (2 trip detection logic)
Combination meter
ABS ECU
Open or short in vehicle speed sensor circuit
Vehicle speed sensor
ECM WIRING DIAGRAM C10 Combination Meter ECM Instrument Panel J/B B 6 L 2A 7 2B V–W G J27 J/C G J28 V–W 5 E10 SPD A14030 INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 2001 PRIUS (RM778U) DI–106 DIAGNOSTICS 1 – ENGINE Check operation of speedometer. CHECK: Drive the vehicle and check if the operation of the speedmeter in the combination meter is normal. HINT: The ABS ECU is operating normally if the speedometer display is normal. NG Check and replace combination meter (See page BE–2) and ABS ECU (See page IN–41). OK 2 Check voltage between terminal SPD of ECM connector and body ground. ON SPD (–) (+) A14009 PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Drive the vehicle. CHECK: Measure voltage between terminal SPD of ECM connector and body ground when the wheel is turned slowly. OK: Voltage is generated intermittently. 4.5 ∼ 5.5 V 0 AT7809 NG OK Check and replace ECM (See page IN–41). 2001 PRIUS (RM778U) Check and repair harness and connector between combination meter and ECM. DI–108 DIAGNOSTICS – ENGINE DI7SW–01 DTC P1125 Throttle Control Motor Circuit Malfunction CIRCUIT DESCRIPTION Throttle motor is operated by the ECM and it opens and closes the throttle valve. The opening angle of the throttle valve is detected by the throttle position sensor which is mounted on the throttle body and it provides feedback to the ECM to control the throttle motor in order to the throttle valve opening angle properly in response to driving condition. If this DTC is stored, the ECM shuts down the power for the throttle motor, and the throttle valve is fully closed by the return spring. DTC No. DTC Detecting Condition Trouble Area Conditions (a) and (b) continue for 0.5 seconds: (a) Throttle control motor output duty
80 % (b) Throttle control motor current < 0.5 A P1125
Open or short in throttle control motor circuit
Throttle control motor
ECM Throttle control motor current
16 A Condition (a) continues for 0.6 seconds: (a) Throttle control motor current
7 A WIRING DIAGRAM Throttle Control Motor with Magnetic Clutch ECM (Shielded) 2 L 1 P 8 E7 M+ 7 E7 M– 30 E7 GE01 A14031 INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting, it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction. 2001 PRIUS (RM778U) DI–109 DIAGNOSTICS 1 – ENGINE Check throttle control motor circuit. M+ Signal Waveform 5 V/ Division GND 1 msec./Division M– Signal Waveform 5 V/ Division PREPARATION: (a) Connect the oscilloscope between terminals M+ or M– and E1 of the ECM connectors. (b) Start the engine. CHECK: Check the waveform between terminals M+ or M– and E1 of the ECM connectors when the engine is idling. OK: The correct waveforms are as shown. HINT: The waveform frequency varies depending on the throttle opening. GND A03403 A03404 1 msec./Division A03675 OK Check and replace ECM (See page IN–41). NG 2 Check throttle control motor (See page SF–24). NG Replace throttle control motor with magnetic clutch (See page SF–29). OK 3 Check for open and short in harness and connector between throttle control motor and ECM (See page IN–41). NG OK Check and replace ECM (See page IN–41). 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–110 DIAGNOSTICS – ENGINE DI2EC–07 DTC P1127 ETCS Actuator Power Source Circuit Malfunction CIRCUIT DESCRIPTION Battery positive voltage is supplied to terminal BM of the ECM even once when the ignition switch is OFF for the electric throttle control system. If this DTC is stored, the ECM shuts down the power for the throttle motor, and the throttle valve is fully closed by the return spring. DTC No. P1127 DTC Detecting Condition Trouble Area
Open in ETCS power source circuit
ECM Open in ETCS power source circuit WIRING DIAGRAM ECM FL Block No. 1 1 1 F12 F13 Engine Room J/B B 2 1B THRO 8 1A GR 6 E7 +BM B–G FL Block No. 2 1 MAIN Battery A14032 INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting, it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction. 2001 PRIUS (RM778U) DI–111 DIAGNOSTICS 1 – ENGINE Check THRO fuse of R/B No.2. PREPARATION: Remove the THRO fuse from the Engine room J/B. CHECK: Check the countinuity of the THRO fuse. OK: Continuity R/B No.2 NG THRO Fuse Check for short in all harness and components connected to THRO fuse. A13630 OK 2 Check voltage between terminal +BM of ECM connector and body ground. PREPARATION: Remove the ECM with connector still connected (See page SF–62). CHECK: Measure the voltage between terminal BM of the ECM connector and body ground. OK: Voltage: 9 – 14 V BM (+) (–) A13631 OK NG Check and repair harness or connector between battery and ETCS fuse, and ETCS fuse and ECM (See page IN–41). 2001 PRIUS (RM778U) Check and replace ECM (See page IN–41). DI–112 DIAGNOSTICS – ENGINE DI7SX–01 DTC P1128 Throttle Control Motor Lock Malfunction CIRCUIT DESCRIPTION Throttle motor is operated by the ECM and it opens and closes the throttle valve. The opening angle of the throttle valve is detected by the throttle position sensor which is mounted on the throttle body and it provides feedback to the ECM to control the throttle motor in order the throttle valve opening angle properly in response to driving condition. If this DTC is stored, the ECM shuts down the power for the throttle motor, and the throttle valve is fully closed by the return spring. DTC No. P1128 DTC Detecting Condition Trouble Area Lock throttle control motor during control throttle control motor
Throttle control motor
Throttle body WIRING DIAGRAM Refer to DTC P1125 on page DI–108. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting, it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction. 1 Check throttle control motor (See page DI–108). NG Replace throttle control motor (See page SF–29). OK 2 Visually check throttle valve. PREPARATION: Remove the intake air resonator. CHECK: Check whether or not a foreign body is caught between the throttle valve and housing. NG 2001 PRIUS (RM778U) Remove foreign body and clean throttle body. DI–113 DIAGNOSTICS OK Replace throttle body. 2001 PRIUS (RM778U) – ENGINE DI–115 DIAGNOSTICS – ENGINE DI6VI–02 DTC P1300 Igniter Circuit Malfunction (No.1) DTC P1305 Igniter Circuit Malfunction (No.2) DTC P1310 Igniter Circuit Malfunction (No.3) DTC P1315 Igniter Circuit Malfunction (No.4) CIRCUIT DESCRIPTION A DIS (Direct Ignition System) has been adopted. The DIS improves the ignition timing accuracy, reduces high–voltage loss, and enhances the the overall reliability of the ignition system by eliminating the distributor. The DIS is a 1–cylinder ignition system which ignites one cylinder with one ignition coil. In the 1–cylinder ignition system, the one spark plug is connected to the end of the secondary winding. High voltage generated in the secondary winding is applied directly to the spark plug. The spark of the spark plug pass from the center elecrtode to the ground electrode. The ECM determines ignition timing and outputs the ignition signals (IGT) for each cylinder. Based on IGT signals, the power transistors in the igniter cuts off the current to the primary coil in the ignition coil is supplied to the spark plug that are connected to the end of the secondary coil. At the same time, the igniter also sends an ignition confirmation signal (IGF) as a fail–safe measure to the ECM. DTC No. P1300 P1305 P1310 P1315 DTC Detecting Condition No IGF signal to ECM while engine is running 2001 PRIUS (RM778U) Trouble Area
Ignition system
Open or short in IGF1 and IGT1 – 4 circuit from ignition coil with igniter
No.1 – No.4 ignition coil with igniter
ECM DI–116 DIAGNOSTICS – ENGINE WIRING DIAGRAM I4 Ignition Coil and Igniter No. 4 1 Y 3 B–W Engine Room J/B IG2 Relay 2 1A 3 3 1K 2 14 E7 IGT4 B–W 5 9 1J 1 3 1J W–B W–R W–B I3 Ignition Coil B–W and Igniter No. 3 3 4 1 AM2 W–B Instrument Panel J/B 2G 11 2 4 B–R G 13 E7 IGT3 B–W B–W 2 1B ECM 2G 1 W–B 2 B–R B–R I2 Ignition Coil and Igniter No. 2 W 3 4 B–W 12 E7 IGT2 B–W 1 B 2B 5 W–B 2C 2 W–B B–W A F12 1 FL Block No. 1 A 2 B–R J7 J/C W–R W–B 6 F13 1 IG2 AM2 7 I1 Ignition Coil B–R and Igniter No. 1 25 1 2 E7 IGF B–W B–R B–R 11 3 Y–G 4 E7 IGT1 B–W Ignition SW W–B B–G A MAIN J1 J/C IE B–W FL Block No. 2 W–B 1 Battery EA N1 Noise Filter A14055 INSPECTION PROCEDURE HINT:




If DTC P1300 is displayed, check No.1 ignition coil with igniter circuit. If DTC P1305 is displayed, check No.2 ignition coil with igniter circuit. If DTC P1310 is displayed, check No.3 ignition coil with igniter circuit. If DTC P1315 is displayed, check No.4 ignition coil with igniter circuit. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 2001 PRIUS (RM778U) DI–117 DIAGNOSTICS 1 – ENGINE Check spark plug and spark (See page DI–65). NG Go to step 4. OK 2 Check for open and short in harness and connector in IGF and IGT signal circuit between ECM and ignition coil with igniter (See page IN–41). NG Repair or replace harness or connector. OK 3 Disconnect ignition coil with igniter connector and check voltage between terminals IGF of ECM connector and body ground. ON IGF (+) (–) A13632 PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Disconnect the ignition coil with igniter connector. (c) Turn the ignition switch ON. CHECK: Measure voltage between terminals IGF of the ECM connector and body ground. OK: Voltage: 4.5 – 5.5 V OK Replace ignition coil with igniter. NG Check and replace ECM (See page IN–41). 4 Check for open and short in harness and connector in IGT signal circuit between ECM and ignition coil with igniter (See page IN–41). 2001 PRIUS (RM778U) DI–118 DIAGNOSTICS NG – ENGINE Repair or replace harness or connector. OK 5 Check voltage between terminals IGT1 – 4 of ECM connector and body ground. ON IGT4 IGT3 IGT2 (+) PREPARATION: Remove the ECM with connector still connected (See page SF–62). CHECK: Measure voltage between terminals IGT1 – 4 of the ECM connector and body ground when engine is cranked. OK: Voltage: More than 0.1 V and less than 4.5 V IGT1 (–) A13633 IGT signal waveform 5 V/ Division IGT GND Reference: INSPECTION USING OSCILLOSCOPE During cranking or idling, check waveform between terminals IGT1 – 4 and E1 of the ECM connector. HINT: Correct waveform appears as sohwn, with rectangle waves. GND IGF 20 m sec./ Division A06097 NG Check and replace ECM (See page IN–41). OK 6 Disconnect ignition coil with igniter connector and check voltage between terminals IGT1 – 4 of ECM connector and body ground. ON IGT4 IGT3 IGT2 (+) IGT1 (–) A13633 2001 PRIUS (RM778U) PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Disconnect the ignition coil with igniter connector. CHECK: Measure voltage between terminals IGT1 – 4 of the ECM connector and body ground when engine is cranked. OK: Voltage: More than 0.1 V and less than 4.5 V DI–119 DIAGNOSTICS NG – ENGINE Check and replace ECM (See page IN–41). OK 7 Check ignition coil with igniter power source circuit. PREPARATION: Disconnect the ignition coil with igniter connector. CHECK: Measure voltage between terminal 1 of ignition coil with igniter connector and body ground, when ignition switch is turned to ”ON” and ”START” position. OK: Voltage: 9 – 14 V 1 ON (+) (–) START A09045 NG Repair ignition coil with igniter power sourcecircuit. OK 8 Check for open and short in harness and connector between ignition switch and ignition coil with igniter (See page IN–41). NG Repair or replace harness or connector. OK 9 Check EFI main relay (Marking: EFI) (See page SF–37). NG OK Replace ignition coil with igniter. 2001 PRIUS (RM778U) Replace EFI main relay (marking: EFI). DI–121 DIAGNOSTICS – ENGINE DI6VL–02 DTC P1349 VVT System Malfunction CIRCUIT DESCRIPTION VVT system controls the intake valve timing to proper timing in response to driving condition. ECM controls OCV (Oil Control Valve) to make the intake valve timing properly, and, oil pressure controlled with OCV is supplied to the VVT controller, and then, VVT controller changes relative position between the camshaft and the crankshaft. DTC No. P1349 DTC Detecting Condition Trouble Area Condition (a) or (b) continues for after the engine is warmed up and engine speed at 400 – 4,000 rpm : (a) Valve timing does not change from of current valve timing (b) Current valve timing is fixed.
Valve timing
Oil control valve
VVT controller assembly
ECM WIRING DIAGRAM ECM C2 Oil Control Valve Y–R 23 E7 OCV+ W–G 24 E7 OCV– 1 2 A09060 INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. TOYOTA hand–held tester 1 Check valve timing (See page EM–21). NG OK 2001 PRIUS (RM778U) Repair valve timing. DI–122 DIAGNOSTICS 2 – ENGINE Check operation of OCV. PREPARATION: (a) Start the engine and warmed it up. (b) Connect the TOYOTA hand–held tester and select VVT from ACTIVE TEST menu. CHECK: Check the engine speed when operate the OCV by the TOYOTA hand–held tester. OK: VVT system OFF to ON (OCV OFF to ON): Engine speed increases. VVT system ON to OFF (OCV ON to OFF): Engine is stalled. HINT: The change of engine speed lasts only few seconds. OK VVT system is OK.* *: DTC P1349 is also output after the foreign object is caught in some part of the system in the engine oil and the system returns to normal in a short time. As ECM controls so that foreign objects are ejected, there is no problem about VVT. There is also no problem since the oil filter should get the foreign object in the engine oil. NG 3 Check voltage between terminals OCV+ and OCV– of ECM connector. OCV Signal Waveform 5 V/ Division (A) (A) (A) GND 1 m sec./Division A02397 OK 2001 PRIUS (RM778U) Reference: INSPECTION USING OSCILLOSCOPE Turn the ignition switch ON, check waveform between terminals OCV+ and OCV– of the ECM connector. HINT:
The correct waveform is as shown.
The waveform frequency (A) is lengthened as the engine speed becomes higher. NG Check and replace ECM (See page IN–41). DI–123 DIAGNOSTICS 4 – ENGINE Check VVT controller assembly (See page EM–33). NG Replace VVT controller assembly, and then go to step 5. OK 5 Check oil control valve (See page SF–35). NG Replace oil control valve, and then go to step 6. OK 6 Check blockage of oil control valve, oil check valve and oil pipe No.1. NG Repair or replace. OK 7 Check whether or not DTC P1349 is stored. PREPARATION: (a) Clear the DTC (See page DI–3). (b) Perform simulation test. CHECK: Check whether or not DTC P1349 is stored (See page DI–3). OK: DTC P1349 is not stored OK VVT system is OK.* *: DTC P1349 is also output after the foreign object is caught in some part of the system in the engine oil and the system returns to normal in a short time. As ECM controls so that foreign objects are ejected, there is no problem about VVT. There is also no problem since the oil filter should get the foreign object in the engine oil. 2001 PRIUS (RM778U) DI–124 DIAGNOSTICS – ENGINE NG Replace ECM. OBD II scan tool (excluding TOYOTA hand–held tester) 1 Check valve timing (See page EM–21). NG Repair valve timing. OK 2 Check operation of OCV. (a) OCV Connector PREPARATION: Start the engine. CHECK: (a) Check the engine speed when disconnect the OCV connector. (b) Check the engine speed when apply battery positive voltage between terminals of OCV. RESULT: (b) Result Check (a) Check (b) 1 Normal engine speed Rough idle or engine stall 2 A14061 A14062 A14465 2 1 2001 PRIUS (RM778U) Go to step 4. Except 1 DI–125 DIAGNOSTICS 3 – ENGINE Check voltage between terminals OCV+ and OCV– of ECM connector. OCV Signal Waveform 5 V/ Division (A) (A) (A) GND 1 m sec./Division A02397 Reference: INSPECTION USING OSCILLOSCOPE Turn the ignition switch ON, check waveform between terminals OCV+ and OCV– of the ECM connector. HINT:
The correct waveform is as shown.
The waveform frequency (A) is lengthened as the engine speed becomes higher. OK VVT system is OK.* *: DTC P1349 is also output after the foreign object is caught in some part of the system in the engine oil and the system returns to normal in a short time. As ECM controls so that foreign objects are ejected, there is no problem about VVT. There is also no problem since the oil filter should get the foreign object in the engine oil. NG Check and replace ECM (See page IN–41). 4 Check VVT controller assembly (See page EM–33). NG Replace VVT controller assembly, and then go to step 5. OK 5 Check oil control valve (See page SF–35). NG OK 2001 PRIUS (RM778U) Replace oil control valve, and then go to step 6. DI–126 DIAGNOSTICS 6 – ENGINE Check blockage of oil control valve, oil check valve and oil pipe No.1. NG Repair or replace. OK 7 Check whether or not DTC P1349 is stored. PREPARATION: (a) Clear the DTC (See page DI–3). (b) Perform simulation test. CHECK: Check whether or not DTC P1349 is stored (See page DI–3). OK: DTC P1349 is not stored OK VVT system is OK.* *: DTC P1349 is also output after the foreign object is caught in some part of the system in the engine oil and the system returns to normal in a short time. As ECM controls so that foreign objects are ejected, there is no problem about VVT. There is also no problem since the oil filter should get the foreign object in the engine oil. NG Replace ECM. 2001 PRIUS (RM778U) DI–127 DIAGNOSTICS – ENGINE DI7SY–01 DTC P1430 Vacuum Sensor for HC Adsorber and Catalyst System Circuit Malfunction CIRCUIT DESCRIPTION DTC No. P1430 DTC Detecting Condition Trouble Area
Open or short in vacuum sensor circuit
Vacuum sensor for HC adsorber and catalyst system
ECM Open or short in vacuum sensor circuit HINT: After confirming DTC P1430, use the hand–held tester to confirm the manifold absolute pressure from the CURRENT DATA. Manifold Absolute Pressure (kPa) Malfunction
HCLS circuit short Approx. 0
VC circuit open or short
HCLS circuit open
E2 circuit open 130 or more WIRING DIAGRAM V1 Vacuum Sensor 3 2 Y–R V–W 1 B J/C J9 ECM C J8 9 I01 Y–R V–W 2 E8 VC 14 E9 HCLS 18 BR E8 E2 A14056 INSPECTION PROCEDURE HINT:

If DTCs P1430,P1431, P0110, P0115, P0120 and P0121 are output simultaneously, E2 (sensor ground) may be open. Read freeze frame data using hand–held tester. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction. 2001 PRIUS (RM778U) DI–128 DIAGNOSTICS – ENGINE When using hand–held tester: 1 Connect hand–held tester, and read value. PREPARATION: (a) Connect the hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the hand–held tester main switch ON. CHECK: Read the value of the manifold absolute pressure on the hand–held tester. OK: Same as atmospheric pressure. OK Check for intermittent problems (See page DI–3). NG 2 Check voltage between terminals VC and E2 of engine ECU Connector. ON VC E2 (+) (–) A13624 PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals VC and E2 of the engine ECU connector. OK: Voltage: 4.5 – 5.5 V NG OK 2001 PRIUS (RM778U) Check and replace engine ECU (See page IN–41). DI–129 DIAGNOSTICS 3 – ENGINE Check voltage between terminals HCLS and E2 of engine ECU connector. ON HCLS A14021 PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals HCLS and E2 of the engine ECU connector. OK: Voltage: 3.3 – 3.9 V OK Check and replace engine ECU (See page IN–41). NG 4 Check for open and short in harness and connector between vacuum sensor and engine ECU. NG Repair and replace harness or connector. OK Replace vacuum sensor (See page SF–50). When not using hand–held tester: 1 Check voltage between terminals VC and E2 of engine ECU connector. ON VC E2 (+) (–) A13624 PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals VC and E2 of the engine ECU connector. OK: Voltage: 4.5 – 5.5 V NG 2001 PRIUS (RM778U) Check and replace engine ECU (See page IN–41). DI–130 DIAGNOSTICS – ENGINE OK 2 Check voltage between terminals HCLS and E2 of engine ECU connector. ON HCLS A14021 PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals HCLS and E2 of the engine ECU connector. OK: Voltage: 3.3 – 3.9 V OK Check and replace engine ECU (See page IN–41). NG 3 Check for open and short in harness and connector between engine ECU and vacuum sensor (See page IN–41). NG OK Replace vacuum sensor. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–131 DIAGNOSTICS – ENGINE DI7SZ–01 DTC P1431 Vacuum Sensor for HC Adsorber and Catalyst System Circuit Range/Performance Problem CIRCUIT DESCRIPTION Refer to DTC P1430 on page DI–127. DTC No. DTC Detecting Condition Trouble Area Conditions (a), (b), (c) and (d) continue with more than 10 seconds: (2 trip detection logic) (b) PIM > 3.96 V (c) VSV for HC Adsorber and Catalyst System is ON (d) Engine speed is 1,000 rpm or more (e) THW
0°C (32°F) P1431 Conditions (a), (b) and (c) continue with more than 10 second: (2 trip detection logic) (a) PIM < 1.2 V (b) Engine stopped (c) VSV for HC Adsorber and Catalyst System is OFF (d) THW
0°C (32°F)
Vacuum sensor for HC adsorber and catalyst system
Vacuum line INSPECTION PROCEDURE HINT:
If DTCs P1430, P1431, P0110, P0115, P0116, P0120, P0121 are output simultaneously, E2 (sensor ground) may be open. Read freeze frame data using hand–held tester. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction. When a bypass valve has a trouble, it is possible that DTC P1341 will be detected ahead of DTC P1436, and P1437, so in case that P1431 even if they are not memorized.

1 Are there any other codes (besides DTC P1431) being output? YES NO 2001 PRIUS (RM778U) Go to relevant DTC chart. DI–132 DIAGNOSTICS 2 – ENGINE Check vacuum sensor for HC adsorber and catalyst system (See page SF–51). NG OK Check vacuum line for vacuum sensor for blockage. 2001 PRIUS (RM778U) Replace vacuum sensor. DI–133 DIAGNOSTICS – ENGINE DI7T0–01 DTC P1436 Bypass Valve Malfunction CIRCUIT DESCRIPTION Before the engine is started, the bypass valve remains open. When the engine is cold started, the ECM outputs a signal to the VSV (for HC adsorber and catalyst system), which open the passage between the intake manifold and the actuator, thus applying a vacuum to the actuator. As a result, the bypass valve closes. Immediately after the engine has started, the exhaust gases pass through the adsorber material in with HC becomes adsorbed and stored for a certain length of time (until the temperature of the front TWC rises). Thus, the release of HC into the atmosphere is prevented when the temperature of the TWC is low. After the TWC has warmed up, the VSV closes the passage between the intake manifold and the actuator, causing the bypass valve to open. Then, as the temperature of the rear TWC rises, the temperature of the adsorber material that surrounds it also rises, and the HC starts to desorb, and becomes cleaned by the TWC. Furthermore, this system activates the VSV when decelerating and the HC adsorber has become the specified temperature, allowing the vacuum from the intake manifold to close the bypass valve in order to scavenge the HC that remains in the adsorber material. DTC No. DTC Detecting Condition P1436 With cold start when the water temperature and intake air temperature were –10 °C (14 °F)to 40 °C (104 °F), and when the water temperature has reached 45 °C (113 °F) or more and the engine load factor has become more than 30 %, the valve operation is not preformed normally. Trouble Area
Vacuum line
Actuator
Front exhaust pipe INSPECTION PROCEDURE 1 Check vacuum hose and tube between VSV and actuator for HC adsorber and catalyst system. CHECK: Check that the vacuum hose and tube for clog and deformation. NG Repair or replace. OK 2 Check actuator operation (See page EC–13). OK NG 2001 PRIUS (RM778U) Recheck after assembly. DI–134 DIAGNOSTICS 3 – ENGINE Check that dirt such as mud is deposited on lever and shaft of bypass valve. YES Remove dirt and check again. NO 4 Check that actuator’s rod and bracket is deformed. YES Repair or replace actuator. NO 5 Check bypass valve operation (See page EC–13). NG Replace front exhaust pipe. OK 6 Check actuator operation (See page EC–13). NG OK Repair or replace front exhaust pipe. 2001 PRIUS (RM778U) Replace actuator. DI–135 DIAGNOSTICS – ENGINE DI7T1–01 DTC P1437 Vacuum Line Malfunction CIRCUIT DESCRIPTION Refer to DTC P1436 on page DI–133. DTC No. DTC Detecting Condition P1437 With cold start when the water temperature and intake air temperature were – 10 °C (14 °F) to 40 °C (104 °F), and when the water temperature has reached 45 °C (113 °F) or more and the engine load factor has become more than 30 %, the negative pressure has abnormality. Trouble Area
Vacuum line
VSV for HC adsober and catalyst system
Vacuum sensor for HC adsober and catalyst system
Check valve INSPECTION PROCEDURE TOYOTA hand–held tester: 1 Check vacuum hoses and tube between intake manifold and actuator. CHECK: (a) Check (b) Check (c) Check (d) Check that the vacuum hoses is connected correctly. the vacuum hose for looseness and disconnection. the vacuum hose and tube for cracks, holes and damage. the vacuum hose for clog. NG Repair or replace. OK 2 Check for open and short in harness and connector between VSV (for HC adsober and catalyst system) and ECM (See page IN–41). NG Repair or replace harness or connector. OK 3 Check VSV (for HC adsorber and catalyst system) (See page SF–47). NG OK 2001 PRIUS (RM778U) Replace VSV. DI–136 DIAGNOSTICS 4 – ENGINE Check vacuum stored in vacuum hose between check valve and actuator. PREPARATION: (a) Disconnect the vacuum hose from the pressure sensor for HC adsober and catalyst system. (b) Connect the MITYVAC (Hand–held vacuum pump) to the vacuum hose. (c) Connect the TOYOTA hand–held tester to the DLC3. CHECK: (a) VSV (for HC adsober and catalyst system) is operate by TOYOTA hand–held tester. (b) Apply vacuum of 55 kPa (420 mmHg, 16.24 in.Hg). (c) Check that the vacuum after 30 sec. OK: The vacuum is 25 Kpa (188 mmHg, 7.38 in.Hg) or more. OK Check and replace vacuum hose between intake manifold and actuator. NG Replace check valve. NG Replace VSV (for HC adsober and catalyst system). NG 5 Check check valve. OK 6 Check stored vacuum of VSV. OK 7 Check stored vacuum of actuator(See page EC–13). NG OK 2001 PRIUS (RM778U) Replace actuator. DI–137 DIAGNOSTICS – ENGINE Check and replace vacuum hose and tube between check valve and actuator. OBD II scan tool (excluding TOYOTA hand–held tester): 1 Check vacuum hoses and tube between intake manifold and actuator. CHECK: (a) Check (b) Check (c) Check (d) Check that the vacuum hoses is connected correctly. the vacuum hose for looseness and disconnection. the vacuum hose and tube for cracks, holes and damage. the vacuum hose and tube for clog. NG Repair or replace. OK 2 Check for open and short in harness and connector between VSV (for HC adsober and catalyst system) and ECM (See page IN–41). NG Repair or replace harness or connector. OK 3 Check VSV (for HC adsober and catalyst system) (See page SF–47). NG OK 2001 PRIUS (RM778U) Replace VSV. DI–138 DIAGNOSTICS 4 – ENGINE Check vacuum stored in vacuum hose between check valve and actuator. ON HCC A14019 PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Disconnect the vacuum hose from the vacuum sensor (for HC adsober and catalyst system). (c) Connect the MITYVAC (Hand–held vacuum pump) to the vacuum hose. CHECK: (a) Connect the terminal HCC of the ECM and body ground. (b) Apply a vacuum of 55 kPa (420 mmHg, 16.24 in.Hg). (c) Check that the vacuum after 30 sec. OK: The vacuum is 25 Kpa (188 mmHg, 7.38 in.Hg) or more. OK Check and replace vacuum hose between check valve and actuator. NG Replace check valve. NG 5 Check check valve. OK 6 Check stored vacuum of VSV (See page SF–47). NG OK 2001 PRIUS (RM778U) Replace VSV for HC adsober and catalyst system. DI–139 DIAGNOSTICS 7 – ENGINE Check stored vacuum of actuator (See page EC–13). NG OK Check and replace vacuum hose and tube between check valve and actuator. 2001 PRIUS (RM778U) Replace actuator. DI–141 DIAGNOSTICS – ENGINE DI7T3–01 DTC P1525 Resolver Vehicle Malfunction CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area P1525 When signals of vehicle speed is not input from the resolver for 16 sec. or more while rurining at a speed of 20 km/h or more
ECM
HV ECU
Wire harness WIRING DIAGRAM ECM HV ECU 6 SPDO H14 O 10 E9 SPHV F02660 2001 PRIUS (RM778U) DI–142 DIAGNOSTICS – ENGINE INSPECTION PROCEDURE 1 Check voltage between terminal SPHV of ECM and body ground. SPHV (–) (+) A14010 PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Drive the vehicle at 20 km/h (12 mph). CHECK: Measure the voltage between SPHV of engine ECU connector and body ground. OK: Voltage is generated intermitlently. 4.5 – 5.5 V 0 A07133 OK Replace engine ECU. NG 2 Check for open and short in harness and connector between SPHV of ECM and SPDO of HV ECU. NG OK Replace HV ECU. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–143 DIAGNOSTICS – ENGINE DI6VN–02 DTC P1600 ECM BATT Malfunction CIRCUIT DESCRIPTION Battery positive voltage is supplied to terminal BATT of the ECM even when the ignition switch is OFF for use by the DTC memory and air–fuel ratio adaptive control value memory, etc. DTC No. DTC Detecting Condition P1600 Trouble Area
Open in back up power source circuit
ECM Open in back up power source circuit HINT: If DTC P1600 appear, the ECM does not store another DTC. WIRING DIAGRAM ECM FL Block No. 1 1 1 F13 F12 B 2 1B Engine Room J/B EFI 4 1A R–W 3 E8 BATT B–G FL Block No. 2 MAIN 1 Battery A14034 INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 2001 PRIUS (RM778U) DI–144 DIAGNOSTICS 1 – ENGINE Check voltage between terminal BATT of ECM connector and body ground. PREPARATION: Remove the ECM with connector still connected (See page SF–62). CHECK: Measure voltage between terminal BATT of the ECM connector and body ground. OK: Voltage: 9 – 14 V LOCK BATT (+) (–) A13634 OK Check and replace ECM (See page IN–41). NG 2 Check EFI fuse. PREPARATION: Remove the EFI fuse from the engine room J/B. CHECK: Check continuity of EFI fuse. OK: Continuity Engine Room J/B NG EFI Fuse A13630 OK Check and repair harness or connector between battery and EFI fuse and ECM (See page IN–41). 2001 PRIUS (RM778U) Check for short in all the harness and components connected to EFI fuse. DI–146 DIAGNOSTICS – ENGINE DI7T4–01 DTC P1636 HV ECU Malfunction CIRCUIT DESCRIPTION DTC No. P1636 DTC Detecting Condition Trouble Area When communication with HV ECU is interrupted for 1.5 sec. or more
Wire harness
HV ECU
ECM WIRING DIAGRAM ECM HV ECU 19 HTE+ H14 29 HTE– H14 19 Y BR E9 HTE+ 18 E9 HTE– I06573 2001 PRIUS (RM778U) DI–147 DIAGNOSTICS – ENGINE INSPECTION PROCEDURE 1 Check voltage between terminal HTE+ and HTE– of ECM. ON HTE+ HTE– (–) (+) PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Turn the ignition swith ON. CHECK: Measure voltage between terminal HTE+ and HTE– of the ECM. OK: A14011 2V/ Div. GND Reference: INSPECTION USING OSCILLOSCOPE Turn the ignition swith ON, check waveform between terminals HTE+ and HTE– of the ECM. HINT: The correct waveform is as shown. 2m sec/ Div. A14012 OK Replace ECM. NG 2 Check for open and short in harness and connector between HTE+ and HTE– of ECM and HTE+ and HTE– of HV ECU (See page IN–41). OK NG Repair or replace harness or connector. 2001 PRIUS (RM778U) Replace HV ECU. DI–148 DIAGNOSTICS – ENGINE DI7T5–01 DTC P1637 ESTP Signal Malfunction CIRCUIT DESCRIPTION DTC No. P1637 DTC Detecting Condition Trouble Area When signal of ESTP is not input from the HV ECU for 2 sec. or more
Wire harness
HV ECU
ECM WIRING DIAGRAM ECM HV ECU 8 ESTP H14 R–Y 16 E9 ESTP F02660 2001 PRIUS (RM778U) DI–149 DIAGNOSTICS – ENGINE INSPECTION PROCEDURE 1 Check voltage between terminal ESTP of ECM and body ground. START ESTP A14013 PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Start the engine. CHECK: Measure voltage between terminal ESTP of ECM and body ground. OK: Voltage: 9 – 14 V OK Replace ECM. NG 2 Check for open and short in harness and connector between ESTP of ECM and HV ECU (See page IN–41). OK NG Repair or replace harness or connector. 2001 PRIUS (RM778U) Replace HV ECU. DI–150 DIAGNOSTICS – ENGINE DI6VO–02 DTC P1656 OCV Circuit Malfunction CIRCUIT DESCRIPTION Refer to DTC P1349 on page DI–121. DTC No. P1656 P1663 DTC Detecting Condition Trouble Area
Open or short in oil control valve circuit
Oil control valve
ECM Open or short in oil control valve circuit WIRING DIAGRAM Refer to DTC P1349 on page DI–121. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. TOYOTA hand–held tester 1 Check OCV circuit. PREPARATION: (a) Start the engine and warmed it up. (b) Connect the TOYOTA hand–held tester and select VVT from ACTIVE TEST menu. CHECK: Check the engine speed when operate the OCV by the TOYOTA hand–held tester. OK: VVT system is OFF (OCV is OFF): Normal engine speed VVT system is ON (OCV is ON): Rough idle or engine stalled OK NG 2001 PRIUS (RM778U) Check for intermittent problems (See page DI–3). DI–151 DIAGNOSTICS 2 – ENGINE Check operation of OCV. A14062 PREPARATION: (a) Start the engine and warmed it up. (b) Disconnect the OCV connector. (c) Apply battery positive voltage between terminals of the OCV. CHECK: Check the engine speed. OK: Rough idle or engine stalled. NG Replace OCV. OK 3 Check voltage between terminals OCV+ and OCV– of ECM connector (See page DI–121). NG Check and replace ECM (See page IN–41). OK 4 Check for open and short in harness and connector between OCV and ECM (See page IN–41). NG OK Check for intermitent problems (See page DI–3). 2001 PRIUS (RM778U) Repair or replace. DI–152 DIAGNOSTICS – ENGINE OBD II scan tool (excluding TOYOTA hand–held tester) 1 Check operation of OCV. A14062 PREPARATION: (a) Start the engine and warmed it up. (b) Disconnect the OCV connector. (c) Apply battery positive voltage between terminals of the OCV. CHECK: Check the engine speed. OK: Rough idle or engine stalled NG Replace OCV. OK 2 Check voltage between terminals OCV+ and OCV– of ECM connector (See page DI–121). NG Check and replace ECM (See page IN–41). OK 3 Check for open and short in harness and connector between OCV and ECM (See page IN–41). NG OK Check for intermitent problems (See page DI–3). 2001 PRIUS (RM778U) Repair or replace. DI–153 DIAGNOSTICS – ENGINE DI7T6–01 DTC P3190 Poor Engine Power DTC P3191 Engine dose not Start CIRCUIT DESCRIPTION From the HV ECU, the ECM receives data such as power output required for the engine (required output), estimated torque produced by the engine (estimated torque), engine RPM of control target (target RPM), whether the engine is in start mode or not. Then, based on the required output and target RPM, the ECM calculates a target torque that is to be produced by the engine and compares it with the estimated torque. If the estimated torque is very low compared with the target torque, or the engine start mode continues at the engine RPM or for the duration calculated by water temperature, an abnormal condition is detected. DTC No. DTC Detecting Condition Trouble Area P3190 Following condition (a) to (e) continues at a fixed engine RPM or a fixed length of time: (a) Communication with HV ECU is normal. (b) Engine RPM is a fixed value or more. (c) Engine star mode is not active. (d) Target torque is a fixed value or more. (e) Ratio of estimated torque against target torque is less than 20 %. P3191 Following condition (a) to (c) continues at a fixed engine RPM or for a fixed length of time: (a) Vommunication with HV ECU is normal. (b) Engine RPM is a fixed value or more. (c) Engine start mode is active.
Air induction system
Throttle body
Fuel pressure
Engine
Air flow meter
Out of fuel
Water W t temp. t sensor
Crankshaft position sensor
Camshaft position sensor
ECM WIRING DIAGRAM Refer to DTC P1636 on page DI–146. INSPECTION PROCEDURE 1 Are there any other codes begin output? YES NO 2001 PRIUS (RM778U) Go to relevant DTC chart. DI–154 DIAGNOSTICS 2 – ENGINE Check remaining amount of fuel. NG Supply fuel. OK 3 Check air induction system (See page SF–1). NG Repair or replace. OK 4 Check for umusual noise or vibration when starting engine or racing. NG Repair or replace. OK 5 Check fuel pressure (See page SF–6). NG Check and repair fuel pump and fuel pipe line (See page SF–19). OK 6 Check air flow meter (See page SF–22) and engine coolant temp. sensor (See page SF–49). NG OK 2001 PRIUS (RM778U) Repair or replace. DI–155 DIAGNOSTICS 7 – ENGINE Check crankshaft position sensor and camshaft position sensor (See page IG–1). NG Repair or replace. OK 8 Check throttle control motor and throttle position sensor (See page SF–24). NG OK Chack and replace ECM (See page IN–41). 2001 PRIUS (RM778U) Repair or replace. DI–156 DIAGNOSTICS – ENGINE DI7DK–02 ECM Power Source Circuit CIRCUIT INSPECTION When the ignition switch is turned on, battery positive voltage is applied to IG2 Relay, terminal IGSW of the ECM and the EFI main relay (Marking: EFI MAIN) control circuit in the ECM sends a signal to terminal MREL of the ECM switching on the EFI main relay. This signal causes current to flow to the coil, closing the contacts of the EFI main relay and supplying power to terminals +B of the ECM. If the ignition switch is turned off, the ECM continues to switch on the EFI main relay for a maximum of 2 seconds for the initial setting of the IAC valve. WIRING DIAGRAM ECM B Engine Room J/B 3 1A EFI Relay 3 5 3 1K 2 12 1F 1 4 IA2 G–R G–R 4 E8 +B 25 E9 MREL EFI AM2 2 1B 9 1J B W–R 2G 1 Instrument Panel J/B FL Block No. 1 1 1 F13 F12 2C 2 W–B J7 J/C A A W–B A B–G W–R 1 MAIN 6 7 F18 FL Block No. 2 AM2 IG2 C J24 J/C B 9 B–W J25 E10 IGSW B–W I15 Ignition SW J1 J/C IE Battery A14058 2001 PRIUS (RM778U) DI–157 DIAGNOSTICS – ENGINE INSPECTION PROCEDURE 1 Check voltage between terminals +B and E1 or ECM connectors. ON +B (+) (–) E1 A13635 PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals +B and E1 of the ECM connectors. OK: Voltage: 9 – 14 V OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–22). NG 2 Check for open in harness and connector between terminal E1 of ECM connector and body ground (See page IN–41). NG Repair or replace harness or connector. OK 3 Check voltage between terminal IGSW of ECM connector and body ground. IGSW (–) (+) A13636 PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminal IGSW of the ECM connector and body ground. OK: Voltage: 9 – 14 V OK NG 2001 PRIUS (RM778U) Go to step 6. DI–158 DIAGNOSTICS 4 – ENGINE Check AM2 fuse. PREPARATION: Remove the AM2 fuse from the engine room J/B. CHECK: Check the continuity of the AM2 fuse. OK: Continuity Engine Room J/B NG AM2 Fuse Check for short in all harness and components connected to AM2 fuse (See attached wiring diagram). A13630 OK 5 Check ignition switch (See page BE–16). NG OK Check and repair harness and connector between battery and ignition switch, and ignition switch and ECM. 2001 PRIUS (RM778U) Replace ignition switch. DI–159 DIAGNOSTICS 6 – ENGINE Check voltage between terminal MREL of ECM connector and body ground. MREL (–) (+) A14004 PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminal MREL of the ECM connector and body ground. OK: Voltage: 9 – 14 V NG Check and replace ECM (See page IN–41). OK 7 Check EFI1 fuse. PREPARATION: Remove the EFI fuse from the engine room J/B. CHECK: Check continuity of EFI fuse. OK: Continuity Engine Room J/B NG EFI Fuse Check for short in all harness and components connected to EFI1 fuse (See attached wiring diagram). A13630 OK 8 Check EFI main relay (Marking: EFI MAIN) (See page SF–37). NG OK 2001 PRIUS (RM778U) Replace EFI main relay. DI–160 DIAGNOSTICS 9 – ENGINE Check for open and short in harness and connector between terminal MREL of ECM and body ground (See page IN–41). NG OK Check and repair harness or connector between EFI1 fuse and battery. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–161 DIAGNOSTICS – ENGINE DI7T7–01 Fuel Pump Control Circuit CIRCUIT DESCRIPTION When starting the engine with ignition switch: HV ECU receives ST signal and decides to start the engine, and send the signal of the engine start prior signal to the engine ECU by the communicatio between the engine ECU and HV ECU. Engien ECU receives that signal and turns ON the circuit opening relay slightly earlier, then turns the fuel pump. When starting the engine in an intermittent operation: With the cranking by MG1, NE signal comes in immediately, so the engine ECU receives the generation of NE signal and turns the fuel pump. (At this time, no refernce of the communication from HV ECU) When stopping the fuel pump: When the signal to stop the engine comes in to the engine ECU from HV ECU from HV ECU side, the fuel pump stops. At the time of the fuel cut opetation such as deceleration by the engine brake, the fuel pump stops. WIRING DIAGRAM Engine Room J/B CIR OPN Relay 1 2 5 1 3 EFI Relay 2 10 1A 9 G–R 1 1F B–R 14 IA1 12 1F G–R 4 IA2 3 1K W–B E8 G–R FC 25 E9 MREL B–R W–B EFI 5 3 2 1B F18 FL Block No. 2 FL Block No. 1 1 1 MAIN 1 F13 F12 B–G 3 F16 Fuel Pump A J7 7 J/C A W–B B A A J17 J/C J1 J/C Battery ECM IE IG A14059 2001 PRIUS (RM778U) DI–162 DIAGNOSTICS – ENGINE INSPECTION PROCEDURE TOYOTA hand–held tester: 1 Connect TOYOTA hand–held tester and check operation of fuel pump (See page DI–3). OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–22). NG 2 Check for ECM power source circuit (See page DI–156). NG Repair or replace. OK 3 Check circuit opening relay (Marking: C/OPN) (See page SF–38). NG Replace circuit opening relay. OK 4 Check voltage between terminal FC of ECM and body ground. ON FC (+) (–) A14007 2001 PRIUS (RM778U) PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminal FC of the ECM and body ground. OK: Voltage: 9 – 14 V DI–163 DIAGNOSTICS OK – ENGINE Go to step 5. NG Check for open in harness and connector between EFI main relay and circuit opening relay (Marking: C/OPN), circuit opening relay and ECM (See page IN–41). 5 Check fuel pump (See page SF–6). NG Repair or replace fuel tank assembly. OK 6 Check for open in harness and connector between circuit opening relay and fuel pump and body ground (See page IN–41). NG OK Check and replace ECM (See page IN–41). 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–164 DIAGNOSTICS – ENGINE OBD II scan tool (excluding TOYOTA hand–held tester): 1 Check operation of fuel pump. ON FC OFF ON Fuel Inlet Hose PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Turn the ignition switch ON. CHECK: (a) Connect between terminal FC of the ECM connector and body ground. (b) Check for fuel pressure in the fuel inlet hose when it is pinched off. OK: There is pressure in fuel inlet hose. HINT: At this time, you will hear a fuel return flowing noise. OK A14005 B10046 Proceed to next circuit inspection shown on problem symptoms table (See page DI–22). A14006 NG 2 Check for ECM power source circuit (See page DI–156). NG Repair or replace. OK 3 Check circuit opening relay (Marking: C/OPN) (See page SF–38). NG OK 2001 PRIUS (RM778U) Replace circuit opening relay. DI–165 DIAGNOSTICS 4 – ENGINE Check voltage between terminal FC of ECM and body ground (See page DI–161). OK Go to step 5. NG Check for open in harness and connector between EFI main relay and circuit opening relay (Marking: C/OPN), circuit opening relay and ECM (See page IN–41). 5 Check fuel pump (See page SF–6). NG Repair or replace fuel tank assembly. OK 6 Check for open in harness and connector between circuit opening relay and fuel pump and body ground (See page IN–41). NG OK Check and replace ECM (See page IN–41). 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–166 DIAGNOSTICS – ENGINE DI6MN–03 MIL Circuit Malfunction CIRCUIT DESCRIPTION If the ECM detects trouble, the MIL lights up. At this time, the ECM records a DTC in memory. HINT: When the ignition switch is ON and ”READY” indicator light is OFF, the bulb check of the ”MIL” is performed (”MIL” is ON). When ”MIL” is ON, but the DTC of the engine is not memorized, it may be because of HV control system abnormality, so check HV control system beforehand. WIRING DIAGRAM ECM Instrument Panel J/B 1 2H W W–B 8 2K IG1 Relay GAUGE 5 2 3 5 2A L 6 2D 1 Combination Meter 6 22 MIL 4 G–R C11 E10 W C10 B–Y Ignition SW AM1 3 2B W–G 2 AM1 IG1 4 A 1 DC/DC 1 B–G 1 F11 F13 FL Block No. 1 J11 J/C MAIN FL Block No. 2 2 Battery ID A14037 INSPECTION PROCEDURE HINT: Troubleshoot in accordance with the chart below for each trouble symptom. MIL does not light up Start inspection from step 1 in case of using TOYOTA hand–held tester and start from step 2 in case of not using TOYOTA hand– held tester MIL remains on After inspection of step 3, start inspection from step 4 in case of using TOYOTA hand–held tester and start from step 5 in case of not using TOYOTA hand–held tester 2001 PRIUS (RM778U) DI–167 DIAGNOSTICS 1 – ENGINE Inspect diagnosis (normal mode, check mode) (See page DI–3). OK Check and replace ECM (See page IN–41). NG 2 Check MIL. See combination meter troubleshooting on page BE–2. NG Repair or replace bulb or combination meter assembly. OK 3 Check that ECM connectors are securely connected to ECM. NO Connect connector to ECM. YES Check for open circuit in harness and connector between combination meter and ECM (See page IN–41). 4 Check operation of MIL (See step 1). OK NG 2001 PRIUS (RM778U) Check and replace ECM (See page IN–41). DI–168 DIAGNOSTICS 5 – ENGINE Is any DTC output? Check DTC on page DI–14. YES Repair circuit indicated by output code. NO 6 Check IG1 relay (Marking: IG1). NG OK Check for short circuit in harness and connector between DLC3 and ECM (See page IN–41). 2001 PRIUS (RM778U) Replace IG1 relay. DI–169 DIAGNOSTICS – ENGINE DI7DL–02 TC Terminal Circuit CIRCUIT DESCRIPTION Terminal TC and CG are located in the DLC3. When connecting these terminals, DTCs in normal mode or test mode can be read through the MIL flashing in the combination meter. WIRING DIAGRAM D2 DLC3 TC J26 J/C P–B E E P–B 13 J24 J/C CG W–B 2 ID1 ECM J16 J/C P–B C C P–B 6 E9 TC Instrument Panel J/B A W–B A 4 8 2D 8 2K W–B A W–B J11 J/C ID A14038 INSPECTION PROCEDURE HINT:

Even though terminal TC is not connected with terminal CG, the MIL blinks. For the above phenomenon,an open or short in the wire harness, or malfunction inside the ECM is the likely cause. 1 Check voltage between terminals TC and CG of DLC3. ON CG (–) (+) TC NG 2001 PRIUS (RM778U) F08565 PREPARATION: Turn the ignition switch ON. CHECK: Measure the voltage between terminals TC and CG of the DLC3. OK: Voltage: 9 – 14 V OK Check and replace ECM (See page IN–41). DI–170 DIAGNOSTICS 2 – ENGINE Check continuity between terminal CG of DLC3 and body ground. NG Repair or replace harness or connector. OK 3 Check for open and short circuit in harness and connector between ECM and DLC3, and DLC3 and body ground (See page IN–41). NG OK Check and replace ECM (See page IN–41). 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–171 DIAGNOSTICS – ENGINE DI7T8–01 A/C Cut Control Circuit CIRCUIT DESCRIPTION This circuit cuts air conditioning operation during vehicle acceleration in order to increase acceleration performance. During acceleration with the vehicle speed at (AT: 25 km/h (16 mph), MT: 40 km/h (25 mph)) or less, engine speed at (AT: 1,200 rpm, MT:1,600 rpm) or less and throttle valve opening angle at 60° or more, the A/C magnet switch is turned OFF for several seconds. WIRING DIAGRAM ECM A/C Control Assembly ACT 5 A8 FI7012 22 P–G E10 A11860 INSPECTION PROCEDURE TOYOTA hand–held tester: 1 Connect the TOYOTA hand–held tester and check operation of air conditioning cut control. PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and TOYOTA hand–held tester main switch ON. (c) Start the engine and air conditioning switch ON. HINT: A/C magnet clutch is turned ON. (d) Select the ACTIVE TEST mode on the TOYOTA hand–held tester. CHECK: Check operation of A/C magnet clutch cut when air conditioning cut control is operated by the TOYOTA hand–held tester. OK: A/C magnet clutch is turned OFF. 2001 PRIUS (RM778U) DI–172 DIAGNOSTICS OK – ENGINE Proceed to next circuit inspection shown on problem symptom table. (See page DI–22) NG 2 Check for open and short in harness and connector between ECM and A/C amplifier. (See page IN–41) NG Repair or replace harness or connector. OK 3 Check voltage between terminal ACT of ECM and body ground. START ACT (–) (+) PREPARATION: (a) Remove the ECM with connector still connected (See page SF–62). (b) Start the engine. CHECK: Measure voltage between terminal ACT of ECM connector and body ground when A/C switch is turned to ON and OFF. OK: A14008 NG OK Check and replace ECM. (See page IN–41) 2001 PRIUS (RM778U) A/C switch condition Voltage ON 9 – 14 V OFF Below 1.5 V Check and replace A/C amplifier. DI–173 DIAGNOSTICS – ENGINE OBDII scan tool (excluding TOYOTA hand–held tester): 1 Check voltage between terminal ACT of ECM and body ground. START ACT (–) PREPARATION: Start the engine. CHECK: Measure voltage between terminal ACT of ECM connector and body ground when A/C switch is turned to ON and OFF. OK: (+) A14008 OK A/C switch condition Voltage ON 9 – 14 V OFF Below 1.5 V Check and repair ECM. (See page IN–41) NG 2 Check for open and short in harness and connector between ECM and A/C amplifier. (See page IN–41) NG OK Check and replace A/C amplifier. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–175 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM DI82J–02 CUSTOMER PROBLEM ANALYSIS CHECK Prius Problem Check Sheet Person in Charge at Headquarters Name of Dealer Person in Charge at Dealer Office Please fill in the blanks within bold frame. Vehicle Specifications Model Code NHW11– Problem Occurrence Date . . . Frame No. Service Entry Date . . Unit No. etc. Vehicle Delivery Date . . Option ( ( ) Navigation ) others( (equipped by ( ) ) MOP ( Registration date ) dealer) Contents of complaint (Status when and before/after occurring in the order of events as correct as possible) km miles . Odometer Reading : ( ) Cold climate . specification Characteristics of Customer ( ) Male Gender ( ) Female Age Occupation Vehicle used before Main use area city area ( )% suburbs ( )% mountain area Interview Results Others ( Frequency in use ( ) ( )% )% times/day or week or month Others Road Condition Driving Condition Vehicle Speed km/h mph ( ) when starting ( ( ( ( ( ) flat road ( ) when starting ( ) up hill ( ) down ( ) right after starting hill incline of ( ) until min. ° /% after starting distance ) when according ( ) until min. km ) When after starting mph normal driving of driving ) when ( ) dry paved road ( ) when shopping decelerating ( ) wet paved road system ) when braking ( ) when shopping ( ( ( ) when parking ( ) when turning ( ) when ABS actuating ( ) others ( ) 2001 PRIUS (RM778U) ( ( ( Others Vehicle Condition HV Battery indication ( ) 4/4 ( ) 3/4 ( ) 2/4 ( ) 1/4 ( ) unidentified Warning light (MIL) ( ) ON ( ) OFF ( ) PS ( ) main battery ( ) HV! Shift position (indication) ( )P ( )R ( )N ( )D ( )B ( ) engine ( ) when operating ( ) charge → ) rough paved road ( ) output Status of engine control ) unpaved road ( ) no indication ( ) brake ( ) while shopping ( ) unidentified ) snowy/frozen ( ) ABS engine road ( ) others ( ) when starting A/C status ) bump/curb ( engine ( ) A/C ( ) FULL ( ) OFF ( ) when revolving ) others ( ) unidentified engine ( ) ) Weather: Temperature: °C °F Brake operation ( ) brake slowly ( ) Brake suddenly ( ) use two pedals system Frequency in occurrence ( ) always ( ) sometimes ( ) only once Fuel level ( ) segments DI–176 DIAGNOSTICS Verification Results of Warning Light ( ) ON ( ) OFF Verification Results of Diagnostic Code ( ) HV HV ( ) HV battery INF. code ( ) output control warning light Vehicle Verification Results HYBRID VEHICLE CONTROL SYSTEM Engine ( ) engine ( ) charge ( ) PS ( ) brake ( ) ABS ( ) others ( – HV battery Brake PS ) Vehicle Inspection Results (Verification items, reason to identify/presume the cause parts, etc.) Duplication Status ( ) always ( ) sometimes ( ) no reproduction Confirmation Results After Repair Replacement Parts ( ( ( problem parts: 2001 PRIUS (RM778U) No/Yes (Sending date: . . ) ) Normal ) reproduction ) others ( ) DI–177 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM DI82K–02 PRE–CHECK 1. (a) (b) B04757 (c) (d) 2. (a) PRECAUTION When distinguishing trouble and replace the defective part, take necessary preventive measures against an electric shock (See page IN–4). Some portions of the wiring harness in the THS vehicle have circuits to which a high voltage is applied. To prevent an electrical shock, be sure to observe the following: (1) Wear insulated gloves during inspection. (2) Remove a service plug and do not start any repair operation before 5 minutes have passed. Then, confirm that the voltage at the output terminals has dropped down to 12 V or less. (3) Use insulated tools during inspection. (4) When disengaging the wiring connectors, hold the connector bodies to avoid pulling the wires. When engaging the wiring connectors, be sure to engage them securely. Do not leave the tools or parts (bolts, nuts, etc.) inside the cabin. Do not carry metallic objects such as mechanical pencils or scales. DIAGNOSIS SYSTEM Description
The HV control ECU has a self–diagnosis system by which malfunction in the computer itself or in THS components is detected and the Hybrid vehicle warning light in the multi–information display are lighted up. A14091 TOYOTA Hand–held Tester DLC3 F12396 2001 PRIUS (RM778U)
To check the Diagnostic Trouble Codes (DTC), connect the hand–held tester to the Data Link Connector 3 (DLC3) on the vehicle. The TOYOTA hand– held tester also enables you to erase the DTC and check freeze frame data and various forms of THS data. DI–178 DIAGNOSTICS –
(b) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 HYBRID VEHICLE CONTROL SYSTEM Freeze frame data: As the freeze frame data records the driving condition when a malfunction is detected, when troubleshooting, it is useful for determining whether the vehicle was running, braked, stopped or reversed. Check the DLC3. The HV control ECU conforms to ISO 14230 for communication. The terminal arrangement of the DLC3 complies with SAEJ1962 and matches the ISO 14230 format. DLC3 A04550 Terminal No. Connection/Voltage or Resistance Condition 7 Bus
Line/Pulse generation During transmission 4 Chassis Ground ↔ Body Ground/1 Ω or less Always 5 Signal Ground ↔ Body Ground/1 Ω or less Always 16 Battery Positive ↔ Body Ground/10 – 15 V Always HINT: If your display shows UNABLE TO CONNECT TO VEHICLE when you have connected the cable of the TOYOTA hand–held tester to the DLC3, turned the motor switch ON and operated the tester, there is a problem in the vehicle or tool.
If communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle.
If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department. 3. INSPECT DIAGNOSIS (a) Check the auxiliary battery. (1) Measure the voltage of the auxiliary battery. Voltage: 10 – 15 V (2) Inspect the auxiliary battery, fuses, fusible links, wiring harness, connectors and ground. 2001 PRIUS (RM778U) DI–179 DIAGNOSTICS (b) – HYBRID VEHICLE CONTROL SYSTEM Check the master warning light. (1) Turn the ignition switch ON and confirm that the master warning light comes on. HINT: If the master warning light does not come on, suspect a burnt fuse, burnt bulb, or open in wiring harness. A14089 (2) B12009 TOYOTA Hand–held Tester When the ”READY” light is ON, the master warning light should go off. If the lamp remains on, the diagnosis system has detected a malfunction in the system or the meassage such as ”When you park your care, make sure you shift to Park P.” and ”The batteries will not charge if the shifter is N” appears on the multi–information display. Since DTC may be stored even though the lamp is OFF, be sure to check DTC. (c) DLC3 F12396 Check the DTC. (1) Prepare a TOYOTA hand–held tester. (2) Connect the TOYOTA hand–held tester to the DLC3. (3) Turn the ignition switch ON and push the TOYOTA hand–held tester main switch ON. (4) Use the TOYOTA hand–held tester to check the DTC, information code and freeze frame data and note them down. (For operating instructions, see the TOYOTA hand–held tester operator’s manual). HINT:

2001 PRIUS (RM778U) For one DTC, the HV diagnosis system can memorize more than one information code and freeze frame data corresponding to them. Therefore, when troubleshooting, check all of the information codes, record the freeze frame data and then start inspection according to the procedures of ”Circuit Inspection”. The HV ECU is communicating with each ECU of the engine brake, HV battery and EMPS. So, if a warning is output from the HV control system, check and record DTCs of all ECUs. (See tables on the following pages.) (5) See a related page to confirm details of the DTC. DI–180 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM HV ECU–DTC & Information # DTC INFORMATION 1 INFORMATION 2 INFORMATION 3 INFORMATION 4 INFORMATION 5 DTC INFORMATION 1 INFORMATION 2 INFORMATION 3 INFORMATION 4 INFORMATION 5 DTC INFORMATION 1 INFORMATION 2 INFORMATION 3 INFORMATION 4 INFORMATION 5 DTC INFORMATION 1 INFORMATION 2 INFORMATION 3 INFORMATION 4 INFORMATION 5 HV ECU–Information & Freezed frame data INFORMATION rpm rpm MG1 REV MG2 REV MG1 TORQ MG2 TORQ N·m N·m W rpm POWER RQST ENGINE SPD Nm % MCYL CTRL POWER SOC WOUT CTRL POWER WIN CTRL POWER W W DRIVE CONDITION INVERT TEMP – MG1 INVERT TEMP – MG2 °F ( °F ( °C) °C) MG1 TEMP °F ( °C) MG2 TEMP PWR RESOURCE VM °F ( °C) V A PWR RESOURCE IB SHIFT SENSOR 1 ACC SENSOR MAIN ENG STOP RQST Yes / No IDLING REQUEST ENGINE FUEL CUT Yes / No Yes / No 2001 PRIUS (RM778U) V HV BATT CH RQST Yes / No HCAC ABSRT RQST ENG WARM UP RQT Yes / No Yes / No STOP SW COND CRUISE CONTROL Yes / No Yes / No V AUX. BATT V EXCLUSIVE INFO1 EXCLUSIVE INFO2 EXCLUSIVE INFO3 EXCLUSIVE INFO4 EXCLUSIVE INFO5 EXCLUSIVE INFO6 LOAD CONDITION DRIVING PATTEN1 DRIVING PATTEN2 MG1 / MG2 DRIVING PATTEN3 IG OFF IN DRVIN Yes / No SG B IN REDUCIN SG N IN REDUC/P Yes / No Yes / No STEP ACC&BRAKE IG OFF TIME Yes / No OCCURRENCE ORDER min – DI–181 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM HV ECU–Operation History Data SHIFT BEF READY LATEST OPER LATEST TRIP 1 BEF LATST OR 1 BEF LATST TRP 2 BEF LATST OR 2 BEF LATST TRP N RANGE CTRL 1 LATEST OPER LATEST TRIP 1 BEF LATST OR 1 BEF LATST TRP 2 BEF LATST OR 2 BEF LATST TRP N RANGE CTRL 2 LATEST OPER LATEST TRIP 1 BEF LATST OR 1 BEF LATST TRP 2 BEF LATST OR 2 BEF LATST TRP STEP ACCEL IN N LATEST OPER LATEST TRIP 1 BEF LATST OR 1 BEF LATST TRP 2 BEF LATST OR 2 BEF LATST TRP AUX. BATT LOW LATEST OPER LATEST TRIP 1 BEF LATST OR 1 BEF LATST TRP 2 BEF LATST OR 2 BEF LATST TRP HV INTERMITTENT LATEST OPER LATEST TRIP 1 BEF LATST OR 1 BEF LATST TRP 2 BEF LATST OR 2 BEF LATST TRP 2001 PRIUS (RM778U) DI–182 DIAGNOSTICS MG2 TEMP HIGH – HYBRID VEHICLE CONTROL SYSTEM LATEST OPER LATEST TRIP 1 BEF LATST OR 1 BEF LATST TRP 2 BEF LATST OR 2 BEF LATST TRP MG1 TEMP HIGH LATEST OPER LATEST TRIP 1 BEF LATST OR 1 BEF LATST TRP 2 BEF LATST OR 2 BEF LATST TRP MG2 INV TEMP HIGH LATEST OPER LATEST TRIP 1 BEF LATST OR 1 BEF LATST TRP 2 BEF LATST OR 2 BEF LATST TRP MG1 INV TEMP HIGH LATEST OPER LATEST TRIP 1 BEF LATST OR 1 BEF LATST TRP 2 BEF LATST OR 2 BEF LATST TRP MAIN BATT LOW LATEST OPER LATEST TRIP 1 BEF LATST OR 1 BEF LATST TRP 2 BEF LATST OR 2 BEF LATST TRP RESIST OVR HEAT LATEST OPER LATEST TRIP 1 BEF LATST OR 1 BEF LATST TRP 2 BEF LATST OR 2 BEF LATST TRP 2001 PRIUS (RM778U) DI–183 DIAGNOSTICS ACCEL MODE 1 – HYBRID VEHICLE CONTROL SYSTEM SHIFT POSITION N·m N·m N·m BRAKE TORQ MG2 TORQ MG1 TORQ VEHICLE SPD mph( ACC THROTTLE OCCURRENCE TRIP ACCEL MODE 2 SHIFT POSITION N·m N·m N·m BRAKE TORQ MG2 TORQ MG1 TORQ VEHICLE SPD mph( ACC THROTTLE OCCURRENCE TRIP ACCEL MODE 3 BRAKE TORQ MG2 TORQ ACC THROTTLE OCCURRENCE TRIP OVER VOLTAGE OVER CURRENT MG2 TEMP HIGH MG1 TEMP HIGH BATTERY FULL CHG RESTRICTION REGN BRK INFECT BATT SAVE RQST DRIVING PATTERN N·m N·m N·m mph( km/h) % Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No BATT LOW VOLT DISCHAG INHIBIT N RANG OVR TIME Yes / No Yes / No BATT HIGH VOLT BATT OVER LOAD BATT HIGH TEMP Yes / No Yes / No Yes / No LOAT CONDITION DRIVING PATTEN DRIVING PATTEN DRIVING PATTEN 2001 PRIUS (RM778U) km/h) % SHIFT POSITION MG1 TORQ VEHICLE SPD REGEN IH FACTOR km/h) % DI–184 DIAGNOSTICS TEMP TRBLE FACT – HYBRID VEHICLE CONTROL SYSTEM ACC TENT TRBLR ABNML COM BR–HV ILK OPERATION FUEL SHORTAGE ENG INDPDENT RQ DC/DC CONV STP Yes / No Yes / No Yes / No ENG WARM UP RQT AIRCON REQUEST Yes / No Yes / No ENG STP INHIBIT HCAC ABSRT RQST HV BATT CH RQST IDLING REQUEST Yes / No Yes / No ENG STOP RQST Yes / No OUTPUT V OVER INPUT V LOW Yes / No Yes / No INPUT V OVER Yes / No OVR HEAT PRTECT DC/DC CONV STOP DC/DC V UNSTLE Yes / No Yes / No Yes / No Yes / No Yes / No OUTPUT STOP DC/DC STOP FACT 2001 PRIUS (RM778U) Yes / No Yes / No Yes / No DI–185 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM Battery ECU TROUBLE CODE BATTERY SOC % KW KW WOUT WIN DELTA SOC IB MAIN BATTERY BATT TEMP 1 BATT TEMP 2 BATT TEMP 3 BATT TEMP 4 BATT INSIDE AIR NORMAL STATUS PRE ONBOARD CH ONBOARD CHARGE % A °F ( °F ( °C) °C) °F ( °F ( °F ( YES / NO YES / NO °C) °C) °C) YES / NO OFF AVE CHG ST COOLING FAN LO COOLING FAN MID YES / NO ON / OFF ON / OFF COOLING FAN HI ON / OFF SBL FAN ST RQST AUX. BATT V EQTR CHARGE ST EQCO DF RERAY ON / OFF CCTL BATT BLOCK V1 BATT BLOCK V2 BATT BLOCK V3 BATT BLOCK V4 BATT BLOCK V5 BATT BLOCK V6 BATT BLOCK V7 BATT BLOCK V8 BATT BLOCK V9 V ON / OFF ON / OFF ON / OFF V V V V V V V V V BATT BLOCK V10 BATT BLOCK V11 BATT BLOCK V12 V V BATT BLOCK V13 BATT BLOCK V14 V V V BATT BLOCK V15 BATT BLOCK V16 BATT BLOCK V17 BATT BLOCK V18 BATT BLOCK V19 2001 PRIUS (RM778U) V V V V V DI–186 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM Engine ECU TROUBLE CODE CALC LOAD ENGINE SPD COOLANT TEMP INTAKE AIR VEHICLE SPD SHORT FT #1 LOND FT #1 FUEL SYS #1 % rpm °F ( °C) °F ( mph ( °C) km/h) % % FUEL SYS #2 ENG RUN TIME BATTERY INJECTOR V ms INJ VOL FB FEL FB COEF A/F LEARN PURGE LEARN % % degree KCS FEEDBACK REQ ENQ TORQ RAM MONITOR ENG RUN SIG ACC RACING SIG ENG WARM UP SIG ENG RUN PERM KW ON / OFF ON / OFF ON / OFF FC STATUS ENG STP LIMIT EMPS ECU TROUBLE CODE TRQ1 TRQ2 WRR WRL MOTOR ACTUAL V V mph ( km/h) mph ( km/h) A COMMAND VALUE STR ANGL VEL THERMISTOR TEMP PIG SUPPLY IG SUPPLY TRQ1 ZERO VAL TRQ2 ZERO VAL 2001 PRIUS (RM778U) °F ( A deg/s °C) V ON / OFF V V DI–187 DIAGNOSTICS TOYOTA hand–held tester (d) DLC3 F12396 – HYBRID VEHICLE CONTROL SYSTEM Clear the DTC after completion of repair. (1) Connect the TOYOTA hand–held tester to the DLC3. Before clearing, check that DTCs and freeze frame data of the HV ECU and the ECU related to the operation history data are reccorded. (2) Operate the TOYOTA hand–held tester to erase the DTC (See the hand–held tester operator’s manual.). 4. FAIL–SAFE CHART If any the following codes is recorded, the HV ECU enters the fail safe mode. DTC code INF. code Trouble area Driving condition B2799 101 Immobilizeer Malfunction C2692 102 Regenerative Brake Check – C2693 103 Regenerative Brake Check – 104 Limited driving 105 Limited driving 106 Limited driving 107 Limited driving 108 P1120 Impossible to drive 109 Limited driving Accelerator Pedal Position Sensor Circuit Malfunction Limited driving 110 Limited driving 111 Limited driving 112 Limited driving 113 Limited driving (Creep vehicle speed) 114 Limited driving (Creep vehicle speed) P1520 115 Stop Light Switch Malfunction Cruise control driving impossible P1566 116 Cruise Control System Malfunction Cruise control driving impossible P1600 117 BATT Malfunction Normal driving 118 119 P1780 120 Impossible to drive/Normal driving when shift position is fixed Park/Neutral Positiont Switch System y Malfunction Impossible to drive/Normal driving when shift position is fixed 123 Limited driving 388 Limited driving HV Battery B tt Malfunction M lf ti 389 P3001 129 HV Battery ECU Malfunction 133 2001 PRIUS (RM778U) Limited driving Limited driving 131 132 Limited driving Limited driving 130 P3004 Impossible to drive 121 125 P3000 Impossible to drive/Normal driving when shift position is fixed Impossible to drive P Power Cable C bl Malfunction M lf ti Normal driving Limited driving DI–188 DIAGNOSTICS 2001 PRIUS (RM778U) HYBRID VEHICLE CONTROL SYSTEM 127 Limited driving 128 Limited driving 134 Impossible to drive 135 Impossible to drive 136 Normal driving 137 Normal driving 138 Limited driving 139 Normal driving 140 Impossible to drive 141 Impossible to drive 142 Impossible to drive 143 Impossible to drive 144 Impossible to drive 145 Impossible to drive 147 Impossible to drive 148 Normal driving 149 Normal driving 150 Impossible to drive 151 Impossible to drive 152 Impossible to drive 153 Impossible to drive 154 Impossible to drive 155 P3100 – 156 Impossible to drive HV ECU Malfunction M lf ti Impossible to drive 157 Impossible to drive 158 Impossible to drive 159 Impossible to drive 160 Impossible to drive 161 Impossible to drive 162 Impossible to drive 163 Impossible to drive 164 Impossible to drive 165 Limited driving 166 Normal driving 167 Limited driving 168 Limited driving 169 Limited driving 170 Limited driving 171 Impossible to drive 172 Impossible to drive 173 Impossible to drive 174 Normal driving 175 Normal driving 176 Normal driving 177 Impossible to drive 178 Impossible to drive DI–189 DIAGNOSTICS P3100 P3101 Impossible to drive 180 Impossible to drive 181 Impossible to drive 182 Impossible to drive 183 Impossible to drive 184 Impossible to drive 185 Impossible to drive 186 Impossible to drive 187 Impossible to drive 188 Limited driving 189 Limited driving 190 Limited driving 191 Limited driving 192 Limited driving 193 HV ECU Malfunction Limited driving 195 Limited driving 196 Limited driving 197 Limited driving 198 Normal driving 199 Limited driving 200 Limited driving 201 Limited driving 202 Limited driving 203 Limited driving 271 Normal driving 310 Limited driving 392 Impossible to drive 393 Impossible to drive 204 Limited driving 205 Engine System Malfunction 207 Limited driving Battery ECU Communication Circuit Malfunction Limited driving 209 Limited driving 211 Limited driving ECM Communication Circuit Malfunction Limited driving 212 Limited driving 394 Limited driving 214 Normal driving Airbag ECU Communication Circuit Malfunction 215 216 2001 PRIUS (RM778U) Limited driving 208 213 P3108 Limited driving Limited driving 210 P3107 Limited driving 194 206 P3106 HYBRID VEHICLE CONTROL SYSTEM 179 238 P3105 – 217 Normal driving Normal driving A/C Am Amplifier lifier Communication Circuit Malfunction Normal driving Normal driving DI–190 DIAGNOSTICS 218 P3110 220 Regenerative brake ineffective Battery ECU Communication Circuit Malfunction Regenerative brake ineffective 222 Regenerative brake ineffective 223 IGCT Relay Malfunction 2001 PRIUS (RM778U) Normal driving 224 Normal driving 225 Normal driving 226 Impossible to drive 228 Impossible to drive System Main Relay Malfunction Impossible to drive 229 Impossible to drive 231 Impossible to drive 232 Limited driving 233 Impossible to drive 234 Regenerative brake ineffective 235 Impossible to drive 236 Normal driving 237 Limited driving 239 Limited driving 240 Impossible to drive 241 Normal driving 242 Limited driving 243 Limited driving 244 Limited driving 245 Limited driving 246 P3120 Regenerative brake ineffective 221 227 P3115 HYBRID VEHICLE CONTROL SYSTEM Regenerative brake ineffective 219 P3109 – 247 Limited driving HV Transaxle T l Malfunction M lf ti Normal driving 248 Normal driving 249 Normal driving 250 Normal driving 253 Limited driving 254 Limited driving 255 Limited driving 256 Limited driving 257 Normal driving 258 Normal driving 259 Normal driving 260 Normal driving DI–191 DIAGNOSTICS 2001 PRIUS (RM778U) HYBRID VEHICLE CONTROL SYSTEM 263 Normal driving 264 Normal driving 265 Normal driving 266 Limited driving 267 Limited driving 268 Limited driving 269 Limited driving 270 Limited driving 272 Normal driving 273 Normal driving 274 Normal driving 275 Normal driving 276 Normal driving 277 Normal driving 278 Limited driving 279 Impossible to drive 280 Limited driving 281 Limited driving 282 Limited driving 283 Limited driving 284 Impossible to drive 285 P3125 – 286 Limited driving Converter & Inverter Assembly Malfunction Limited driving 287 Limited driving 288 Limited driving 289 Limited driving 290 Limited driving 291 Limited driving 292 Limited driving 293 Limited driving 294 Limited driving 295 Limited driving 296 Limited driving 297 Limited driving 298 Limited driving 299 Limited driving 300 Limited driving 301 Limited driving 302 Limited driving 303 Limited driving 304 Limited driving 305 Limited driving 306 Limited driving 307 Limited driving 308 Impossible to drive DI–192 DIAGNOSTICS Limited driving 311 Normal driving 312 Normal driving 313 Normal driving 314 Normal driving 315 Normal driving 316 Limited driving 317 Limited driving 318 Limited driving 319 Limited driving 320 Limited driving 321 Limited driving 322 Limited driving 323 Limited driving 324 Limited driving 325 Limited driving 326 Limited driving 328 P3145 2001 PRIUS (RM778U) Limited driving 330 Limited driving 331 Limited driving 332 Limited driving 333 Limited driving 334 Limited driving 335 Limited driving 336 Limited driving 337 Limited driving 338 Limited driving 339 Limited driving 340 Limited driving 341 Limited driving 342 Limited driving 343 Limited driving 344 Limited driving 345 Limited driving 347 349 Inverter Cooling System MalMal function Normal driving Circuit Breaker Sensor Mal Malfunction Normal driving 350 P3140 Limited driving Limited driving 348 P3135 Converter & Inverter AssemAssem bly y Malfunction 329 346 P3130 HYBRID VEHICLE CONTROL SYSTEM 309 327 P3125 – 351 352 Normal driving Normal driving Normal driving I t l kM Interlock Malfunction lf ti Vehicle Speed Sensor Circuit Malfunction Normal driving Cruise control driving impossible DI–193 DIAGNOSTICS 5. (a) (b) (c) 6. – HYBRID VEHICLE CONTROL SYSTEM CHECK FOR INTERMITTENT PROBLEMS Perform a simulation test (See page IN–41). In the simulation test, reproduce the driving condition at the trouble occurrence according to the customer’s comments and freeze frame data recorded with DTC, such as an opening angle of the accelerator pedal, SOC, engine coolant temperature, engine rpm, and MG/1MG2 rpm and torque. Check the connector and terminal (See page IN–41). Handle the connector (See page IN–41). TOYOTA HAND–HELD TESTER DISPLAY ITEMS TOYOTA Hand–held tester display Measurement Item 1 BEF LATST OR Number of operation of 1 trip before last 1 BEF LATST TRP Number of trips before last 2 BEF LATST OR Number of operation 2 trips before last 2 BEF LATST TRP Number of trips 2 before last ABNML CON BR–HV Communication malfunction between HV ECU and brake ACC SENSOR MAIN Main accelerator sensor ACC SENSOR SUB Sub accelerator sensor ACC TENT TRBLE Tentative trouble of accelerator ACC THROTTLE Accelerator throttle ACCEL MODE History of acceleration and reduction AIR CON REQUEST Air conditioner request AUX. BATT LOW Auxiliary battery becomes week AUX. BATT V Voltage of auxiliary battery BATT HIGH TEMP Temperature of the battery is too high BATT HIGH VOLT Voltage of the battery is too high BATT LOW BOLT Voltage of the battery is low BATT OVER LOAD Battery is overloaded BATT SAVE RQST Request to save the main battery BATTERY FULL Battery full BRAKE TORQ Brake torque CELL TEMP–MAX Highest temperature of all battery cells CELL TEMP–MIN Lowest temperature of all battery cells CHG RESTRICTION Charge restriction COOLANT TEMP Water temperature CRUISE CONTROL Condition of the cruise control DC/DC CONV STOP DC/DC converter stop signal DC/DC CONV STOP Factors causing DC/DC converter to stop DC/DC STOP FACT DC/DC converter has stopped at least once DC/DC V UNSET DC/DC voltage is unsettled DCHG RQST SOC Discharge request to adjust SOC DISCHAG INHIBIT Battery is inhibited to discharge 2001 PRIUS (RM778U) DI–194 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM 0: When engine is stopped 1: When stopping engine 2: When starting engine DRIVE CONDITION 3: When cranking engine or engine is operating 4: While generating power or load driving 5: – 6: While racing engine in P position DRIVING PATTEN1 History of driving pattern 1 DRIVING PATTEN2 History of driving pattern 2 DRIVING PATTEN3 History of driving pattern 3 DRIVING PATTERN HIstory of driving ECU TYPE ECU type ENG INDPDET RQ Factors causing engine to run independently ENG STOP RQST Engine stop request ENG STP INHIBIT Engine stop inhibition ENG WARM UP RQT Engine warming up request ENGINE FUEL CUT Engine fuel cut ENGINE SPD Engine speed EXCLUSIVE INFO1 Exclusive information 1 EXCLUSIVE INFO2 Exclusive information 2 EXCLUSIVE INFO3 Exclusive information 3 EXCLUSIVE INFO4 Exclusive information 4 EXCLUSIVE INFO5 Exclusive information 5 EXCLUSIVE INFO6 Exclusive information 6 FUEL SHORTAGE Low fuel HCAC ABSRT RQST HCAC OBD request HV BATT CH RQST Request from HV ECU to charge the battery HV ECU INTERMITTENT HV ECU intermittent problems IDLING REQUEST Engine idling request IG OFF IN DRVIN Turning IG OFF while driving the car IG OFF TIME IG OFF time ILK OPERATION Interlock operation INFORMATION 1–5 Information code INPUT V LOW Input voltage is too low INPUT V OVER Input voltage is too high INTAKE AIR Intake air temperature INVERT TEMP–MG1 Temperature of inverter MG1 INVERT TEMP–MG2 Temperature of inverter MG2 LATEST OPER Latest number of operation LATEST TRIP Latest number of trips (IG ON–OFF) LOAD CONDITION Indicating which of MG1 or MG2 the vehicle uses more MAIN BATT LOW SOC of main battery becomes low MCYL CTRL POWER Torque for controlling oil pressure of master cylinder MG1 TEMP HIGH Temperature MG1 is too high MG2 TEMP HIGH Temperature MG2 is too high MG1 CURRENT V Electric current of MG1 V phase 2001 PRIUS (RM778U) DI–195 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM MG1 CURRENT W Electric current of MG1 W phase MG1 INV TEMP HI Temperature of inverter MG1 is high MG1 REV MG1 revolution MG1 TEMP Motor temperature of MG1 MG1 TEMP HIGH Temperature fo MG1 is too high MG2 TEMP HIGH Temperature fo MG2 is too high MG1 CURRENT V Electric cuurent of MG1 is V phase MG1 CURRENT W Electric cuurent of MG1 is W phase MG1 INV TEMP HI Temperature of inverter MG1 is higt MG1 REV MG1 revolution MG1 TEMP Motor temperature of MG1 MG1 TEMP HIGH Temperature of MG1 is high MG1 TORQ MG1 torque MG2 CURRENT V Electric cuurent of MG2 is V phase MG2 CURRENT W Electric cuurent of MG2 is W phase MG2 INV TEMP HI Temperature of inverter MG2 is higt MG2 REV MG2 revolution MG2 TEMP Motor temperature of MG2 MG2 TEMP HIGH Temperature of MG2 is high MG2 TORQ MG2 torque N RANGE OVR TIME Leaving shift gear into N position over a period of time N RANGE CTRL1 N position control due to incomplete shift gears N RANGE CTRL2 N position control due to rapid shift gear (D–R) OCCURRENCE ORDR Order in which the trouble occurs OCCURRNCE TRIP Number of trips when this error occurred OUTPUT STOP Output stop OUTPUT V OVER Output voltage is too high OVER CURRENT Electric current of the batytery is too high OVER VOLTAGE Voltage of the battery is too high OVR HEAT PRTECT Overheat protection POWER RQST Power output requested by HV ECU PWR RESOURCE IB Power resource IB PWR RESOURCE VM power resource VM RAPID SPD CHANG Vehicle speed is changed too rapidly REGEN EXEC TORQ Torque volue of regenerative brake REGEN IH FACTOR Inhibiting factor of regeneration REGEN RQST TORQ Torque valueof regenerative brake requested by HV ECU REGN BRK INEFCT Regenerative brake is ineffective RESIST OVR HEAT Restriction resist is overheating SG B IN REDUCIN Shifting gear into ”B” in reducing the speed SG N IN REDUC/P Shifting gear into ”N” reducing the speed SHIFT BEF READY Shifting gear before ”READY” light turns on SHIFT POSITION Shift position SHIFT SENSOR1 Shift sensor 1 SHIFT SENSOR2 Shift sensor 2 SOC 2001 PRIUS (RM778U) Stated of charge DI–196 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM STEP ACC&BRAKE Stepping both accelerator & brake at the same time STEPP ACC IN N Stepping accelerator in N position STOP SW COND Condition of stop switch STP CIRCIT OPEN STP circuit short STP IN CIR MLF STP circuit malfunciton TACHO METER Engine rpm TARGET ENG SPD Target engine speed TEMP TRBLE FACT Factors causing temporay trouble VEHICLE SPD Vehicle speed WIN CTRL POWER Power value of charge control WOUT CTRL POWER Power value of discharge control 2001 PRIUS (RM778U) DI–197 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM DI82L–02 DIAGNOSTIC TROUBLE CODE CHART HINT: Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument or other factors. If a malfunction code is displayed during the DTC check in the check mode, check the circuit for that code listed in the table below. For the details of each code, turn to the page referred to under the ’’See page’’ for the respective ’’DTC No.’’ in the DTC chart. DTC No. (See page) Detection Item Trouble Area
Wire Harness
Immobilizer System Hybrid System Warning Light* Memory   B2799 (DI–210) Immobilizer Malfunction C2692 (DI–212) Regenerative Brake Check –   C2693 (DI–212) Regenerative Brake Check – X  P1120 (DI–213) Accelerator Pedal Position Sensor Circuit Malfunction
Accelerator Pedal Position Sensor
Wire Harness   P1520 (DI–215) Stop Light Switch (Cruise Control System) Malfunction
Stop Light Switch
Wire Harness
Brake ECU X  P1566 (DI–217) Cruise Control System Malfunction
Stop Light Switch
Brake ECU
Wire Harness X  P1600 (DI–219) BATT Malfunction
HV Fuse
Wire Harness   P1780 (DI–221) Park/Neutral Position Switch System Malfunction
Park/Neutral Position Switch
Wire Harness   P3000 (DI–223) HV Battery Malfunction
HV Battery System
High Voltage Fuse
Power Cable
HV Battery Cooling System /X  P3001 (DI–224) HV Battery ECU Malfunction
Battery ECU   Power Cable Malfunction
Power Cable
HV Battery System
Service Plug
System Main Relay
Converter & Inverter Assembly /X  P3100 (DI–229) HV ECU Malfunction
Wire Harness
HV ECU
ECM
Crankshaft Position Sensor
Camshaft Position Sensor
Ignition Switch   P3101 (DI–237) Engine System Malfunction
Engine
HV Transaxle   P3105 (DI–238) Battery ECU Communication Circuit Malfunction
Wire Harness
Battery ECU   P3106 (DI–240) ECM Communication Circuit Malfunction
Wire Harness
ECM /X  P3004 (DI–225) 2001 PRIUS (RM778U) DI–198 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM P3107 (DI–242) Airbag ECU Communication Circuit Malfunction
Wire Harness
Airbag Sensor Assembly   P3108 (DI–244) A/C Amplifier Communication Circuit Malfunction
Wire Harness
A/C Amplifier X  P3109 (DI–245) Brake ECU Communication Circuit Malfunction
Wire Harness
Brake ECU   P3110 (DI–247) IGCT Relay Malfunction
Wire Harness
IGCT Relay   P3115 (DI–249) System Main Relay Malfunction
Wire Harness
System Main Relay
HV ECU   P3120 (DI–252) HV Transaxle Malfunction
HV Transaxle
Wire Harness
System Main Relay   P3125 (DI–266) Converter & Inverter Assembly Malfunction
Converter & Inverter Assembly
Wire Harness   P3130 (DI–302) Inverter Cooling System Malfunction
Inverter Water Pump
Wire Harness
IG2 Relay
Electric Cooling Fan System   P3135 (DI–305) Circuit Breaker Sensor Malfunction
Circuit Breaker Sensor
Wire Harness   P3140 (DI–307) Interlock Malfunction
Interlock Switch
Inverter Terminal Cover
Converter & Inverter Assembly
Wire Harness   P3145 (DI–310) Vehicle Speed Sensor Circuit Malfunction
Wire Harness X  *: : Hybrid system warning light lights up. 2001 PRIUS (RM778U) X: Hybrid system warning light does not light up. DI–199 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INFORMATION CODE (TOYOTA Hand–held tester only) DTC NO. INF. Code B2799 101 Immobilizer Malfunction Detection Item No input of signal from transponder key ECU C2692 102 Regenerative Brake Check Regenerative brake check C2693 103 Regenerative Brake Check Regenerative brake check 104 Open or short in main accelerator sensor circuit 105 +B short in main accelerator sensor circuit 106 Main sensor internal error 107 Open or short in sub accelerator sensor circuit 108 P1120 Detecting Condition 109 +B short in sub accelerator sensor circuit Accelerator Pedal Position Sensor Circuit Malfunction Sub sensor internal error 110 When difference between main sensor value and sub sensor value is large 111 When sub sensor value changes while main sensor value does not 112 When main sensor value changes while sub sensor value does not 113 When any of the information code 104 – 112 continues to appear 114 Accelerator pedal not smoothly returning to original position P1520 115 Stop Light Switch (Cruise Control System) Malfunction Open or short in stop light switch circuit P1566 116 Cruise Control System Malfunction When STP signal of HV ECU is inconsistent with that of brake ECU, with cruise control indicator ON P1600 117 BATT Malfunction HV ECU back–up power source circuit malfunction 118 When more than 2 main signals are ON 119 P1780 120 When main signal is not turned ON even though sub signal has been input Park/Neutral P k/N t l P Position iti S Switch it h System Malfunction When shift position detected by main signal is different from that detected by sub signal 121 123 125 P3000 P3001 Input of abnormal signal from battery ECU (HV battery system malfunction) HV Battery B tt Malfunction M lf ti Discharge Inhibition Control Malfunction When charged battery is low due to leaving the vehicle in N position, gas shortage or HV system malfunction 389 Drop of High Voltage When main battery is dead or main battery is dead due to HV system malfunction 129 HV Battery ECU Malfunction Battery ECU malfunction 130 HV Battery Malfunction When HV battery voltage becomes lower than inverter voltage P3004 When main fuse is blown out, service plug is disconnected or limiter resistance is cut off P Power Cable C bl Malfunction M lf ti 132 133 HV Battery Malfunction 134 135 2001 PRIUS (RM778U) Input of abnormal signal from battery ECU (high voltage fuse blown out) 388 131 P3100 Open or short in sub sensor circuit When inverter voltage sensor is malfunctioning or limiter resistance value increases Input of abnormal signal from battery ECU HV ECU Internal Error HV ECU IInternal t lE Error HV ECU Internal Error 136 GO Signal Error Open or short in GO signal circuit 137 Engine Speed Sensor Malfunction Engine speed sensor malfunction DI–200 DIAGNOSTICS DTC NO. INF. Code IB Circuit Malfunction Open or short in IB terminal circuit of HV ECU When the difference between battery current of HV ECU and current of battery is large 139 IG Signal Circuit Malfunction HV ECU internal error 140 RAM Braked HV ECU internal error 141 ROM Braked HV ECU internal error 142 ST Signal Circuit Malfunction When ST signal of HV ECU is ON, with ignition switch turned OFF 143 Immobilizer Malfunction HV ECU internal error 144 HV ECU internal error 145 146 HV ECU internal error Pi Primary Check Ch k Malfunction M lf ti 147 392 393 HV ECU internal error M t CPU Malfunction Motor M lf ti HV CPU Operation Malfunction 148 149 HV ECU internal error HV ECU internal error 391 HV ECU internal error HV ECU internal error HV ECU internal error HV CPU Malfunction M lf ti HV ECU internal error 150 HV ECU internal error 151 HV ECU internal error 152 HV ECU internal error 153 Motor CPU Malfunction HV ECU internal error 154 HV ECU internal error 155 HV ECU internal error 156 HV ECU internal error 157 158 159 160 HV ECU internal error M t CPU Malfunction Motor M lf ti Motor ECU Communication Circuit Malfunction 161 163 HV ECU internal error HV ECU internal error HV ECU internal error HV ECU internal error 162 HV ECU internal error Motor ECU Power Source Malfunction HV ECU internal error 164 HV ECU internal error 165 HV ECU internal error 271 Motor PWN Line Connection Malfunction HV ECU internal error 166 HV ECU internal error 167 HV ECU internal error 168 2001 PRIUS (RM778U) Detecting Condition +B short in IB terminal circuit of HV ECU 138 P3100 HYBRID VEHICLE CONTROL SYSTEM Detection Item 127 128 – Motor R/D Malfunction HV ECU internal error 169 HV ECU internal error 170 HV ECU internal error DI–201 DIAGNOSTICS DTC NO. INF. Code 175 176 Motor REF Signal Malfunction Motor Inverter Current Sen Sensor Malfunction Motor Gate Shutdown Signal Line Connection Malfunction HV ECU internal error HV ECU internal error Motor Main CPU Malfunction HV ECU internal error 179 HV ECU internal error 180 HV ECU internal error 181 HV ECU internal error 183 HV ECU internal error Rotation Angle Check CPU Malfunction HV ECU internal error 184 HV ECU internal error 185 HV ECU internal error 186 187 HV ECU internal error Important RAM Malfunction HV ECU internal error 188 HV ECU internal error 189 HV ECU internal error 190 HV ECU internal error 191 HV ECU internal error 192 Generator CPU Malfunction HV ECU internal error 193 HV ECU internal error 194 HV ECU internal error 195 HV ECU internal error 196 HV ECU internal error 310 Generator PWN Line Connection Malfunction HV ECU internal error 197 HV ECU internal error 198 HV ECU internal error 199 200 HV ECU internal error G Generator t R/D M Malfunction lf ti HV ECU internal error 201 HV ECU internal error 202 HV ECU internal error 203 Generator Shutdown Signal Line Connection Malfunction HV ECU internal error 390 Charge Inhibition Control Malfunction HV ECU internal error 204 P3101 HV ECU internal error HV ECU internal error 182 P3100 HV ECU internal error HV ECU internal error 177 178 Detecting Condition HV ECU internal error 173 174 HYBRID VEHICLE CONTROL SYSTEM Detection Item 171 172 – 205 238 Input of abnormal signal from the ECM (abnormal engine output) E i S Engine System t M Malfunction lf ti Input of abnormal signal from the ECM (engine unable to start) Transaxle Malfunction When engine does not start even though cranking it Battery ECU Communication Circuit Malfunction When communication between battery ECU and HV ECU is abnormal 1 sec after ignition is turned ON sec. 206 P3105 207 208 2001 PRIUS (RM778U) DI–202 DIAGNOSTICS DTC NO. INF. Code – HYBRID VEHICLE CONTROL SYSTEM Detection Item Detecting Condition 209 210 P3106 211 ECM Communication Circuit Malfunction When communication between ECM and HV ECU is abnormal 1 sec. after ignition is turned ON 212 Input of abnormal signal from ECM 394 When ECM does not operate 213 P3107 214 Airbag ECU Communication Circuit Malfunction When communication between airbag ECU and HV ECU is abnormal 10 sec after ignition is turned ON sec. A/C Am Amplifier lifier Communication Circuit Malfunction Wh communication When i ti ffrom A/C amplifier lifi tto HV ECU iis abnormal b l 215 216 P3108 217 218 219 P3109 220 Brake ECU Communication Circuit Malfunction When communication between brake ECU and HV ECU is abnormal 1.5 sec. after ignition g is turned ON 221 222 P3110 223 When abnormal data is received from brake ECU IGCT Relay 224 225 Open or +B short in system main relay No. 1 circuit SMR Cont1 C t1 Malfunction M lf ti 226 227 P3115 Deposit De osit of SMR System main relay – terminal deposited 233 System main relay + & – terminal deposited 234 Small reduction of motor magnetism 236 Large reduction of motor magnetism E Energy Balance B l Malfunction M lf ti Small reduction of generator magnetism 237 Large reduction of generator magnetism 239 Shaft damaged 240 241 Generator locked HV Transaxle T l Malfunction M lf ti Torque limiter sliding 242 Planetary gear locked 243 Motor resolver inter–phase short 244 Motor resolver inter–phase short (When there is a history that the state of malfunction continued during inverter fail safe mode) 245 246 2001 PRIUS (RM778U) Short in system main relay No. 3 circuit System main relay + terminal deposited 235 P3120 Short in system main relay No. 2 circuit Open or +B short in system main relay No. 3 circuit SMR Cont3 C t3 Malfunction M lf ti 231 232 Short in system main relay No. 1 circuit Open or +B short in system main relay No. 2 circuit SMR Cont2 C t2 Malfunction M lf ti 228 229 When IGCT relay is always closed M t Resolver Motor R l Malfunction M lf ti Open or short in motor resolver circuit Open or short in motor resolver circuit (When there is a history that the state of malfunction continued during inverter fail safe mode) DI–203 DIAGNOSTICS DTC NO. INF. Code 249 P3120 GND short in motor temperature sensor Motor Tem Temperature erature Sensor Malfunction Motor temperature sensor malfunction Open or +B short in motor temperature sensor Motor temperature sensor performance problem 253 Generator resolver inter–phase short 254 Generator resolver inter–phase short (When there is a history that the state of malfunction continued during inverter fail safe mode) 255 Generator Resolver Malfunc Malfunction Open or short in generator resolver circuit 256 Open or short in generator resolver circuit (When there is a history that the state of malfunction continued during inverter fail safe mode) 257 GND short in generator temperature sensor 259 Generator Temperature Tem erature SenSen sor Malfunction Generator temperature sensor malfunction Open or +B short in generator temperature sensor 260 Generator temperature sensor performance problem 263 +B short in DCDC converter NODD wiring 264 DCDC Converter Malfunction DCDC converter malfunction 265 Open or GND short in DCDC converter NODD wiring 266 Open or GND short in inverter voltage signal circuit 267 +B short in inverter voltage signal circuit 268 269 Inverter voltage signal is inconsistent with battery voltage VM Malfunction Inverter voltage sensor malfunction Abnormality of line connection of inverter voltage signal circuit (When there is a history that the state of malfunction continued during inverter fail safe mode) 270 272 Motor PWN Line Connection Malfunction Abnormality of line connection of motor PWM (When there is a history that the state of malfunction continued during inverter fail safe mode) 273 Motor Inverter Gate Malfunction Motor inverter malfunction 274 275 Open or +B short in motor inverter temperature sensor M t IInverter Motor t T Temperature t 276 277 GND short in motor inverter temperature sensor Motor inverter temperature sensor malfunction S Sensor M lf Malfunction ti Motor inverter temperature sensor performance problem 278 +B short in motor inverter stop signal circuit 279 Over voltage of inverter 280 Motor Inverter Sinv Open or GND short in motor inverter stop signal circuit 281 Voltage drop of inverter power source 282 Inverter circuit broken 283 +B short in motor inverter fail signal circuit 284 Inverter overheating 285 2001 PRIUS (RM778U) Detecting Condition 250 258 P3125 HYBRID VEHICLE CONTROL SYSTEM Detection Item 247 248 – Motor Inverter Finv Open or GND short in motor inverter fail signal circuit 286 Inverter circuit broken 287 Inverter internal short DI–204 DIAGNOSTICS DTC NO. INF. Code Detecting Condition 288 Motor inverter current sensor malfunction (V phase sub sensor) 289 Open in motor inverter current sensor (V phase sub sensor) 290 Motor inverter current sensor malfunction (V phase main sensor) 291 (when there is a history that the state of malfunction continued during inverter fail safe mode) 292 Open in motor inverter current sensor (V phase main sensor) 293 (when there is a history that the state of malfunction continued during inverter fail safe mode) 295 Motor inverter current sensor V phase performance problem Motor M t IInverter t C Currentt S Sensor Malfunction (when there is a history that the state of malfunction continued during inverter fail safe mode) 296 Motor inverter current sensor malfunction (W phase sub sensor) 297 Open in motor inverter current sensor (W phase sub sensor) 298 Motor inverter current sensor malfunction (W phase main sensor) 299 (when there is a history that the state of malfunction continued during inverter fail safe mode) 300 Open in motor inverter current sensor (W phase main sensor) 301 (when there is a history that the state of malfunction continued during inverter fail safe mode) 302 303 304 305 Motor inverter current sensor W phase performance problem Motor M t IInverter t C Currentt S Sensor Malfunction Motor Gate Shutdown Signal Line Connection Malfunction (when there is a history that the state of malfunction continued during inverter fail safe mode) +B short in motor gate shutdown signal circuit Open or GND short in motor gate shutdown signal circuit 306 Failure in Monitoring Motor Torque Performance Failure in monitoring motor torque performance 307 Abnormal Current Value of Motor Abnormal current value of motor 308 Detection of Collision Signal Input of collision signal from airbag or inverter 309 Motor PWM Line Connection Malfunction Open or short in generator inverter switching wiring (GUU, GVU, GWU) 311 Generator Inverter Malfunction Generator inverter malfunction 312 313 314 Open or +B short in generator inverter temperature sensor Generator Inverter Tem Temperaera ture Sensor Malfunction GND short in generator inverter temperature sensor Generator inverter temperature sensor malfunction 315 Generator inverter temperature sensor performance problem 316 +B short in generator inverter stop signal circuit 317 Over voltage of inverter 318 Generator Inverter Sinv Open or GND short in generation inverter stop signal circuit 319 Voltage drop of inverter power source 320 Inverter circuit broken 321 +B short in generator inverter fail signal circuit 322 Inverter overheating 323 2001 PRIUS (RM778U) HYBRID VEHICLE CONTROL SYSTEM Detection Item 294 P3125 – Generator Inverter Finv Open or GND short in generator inverter fail signal circuit 324 Inverter circuit broken 325 Inverter internal short DI–205 DIAGNOSTICS DTC NO. INF. Code 327 Open in generator inverter current sensor (V phase sub sensor) 328 Generator inverter current sensor malfunction (V phase main sensor) 329 (when there is a history that the state of malfunction continued during inverter fail safe mode) 330 Open in generator inverter current sensor (V phase main sensor) 331 (when there is a history that the state of malfunction continued during inverter fail safe mode) 332 Generator inverter current sensor V phase performance problem 333 (when there is a history that the state of malfunction continued during inverter fail safe mode) Generator Inverter Current Sensor Malfunction Open in generator inverter current sensor (W phase sub sensor) 336 Generator inverter current sensor malfunction (W phase main sensor) 337 (when there is a history that the state of malfunction continued during inverter fail safe mode) 338 Open in generator inverter current sensor (W phase main sensor) 339 (when there is a history that the state of malfunction continued during inverter fail safe mode) 340 Generator inverter current sensor W phase performance problem 341 (when there is a history that the state of malfunction continued during inverter fail safe mode) Motor Gate Shutdown Signal Line Connection Failure in monitoring generator torque performance 345 Abnormal Current Value of Generator Abnormal current value of generator 347 349 Inverter Cooling System MalMal function Water pump system malfunction Circuit Breaker Sensor Mal Malfunction GND short in circuit breaker sensor 350 2001 PRIUS (RM778U) Open or GND short in generator gate shutdown signal circuit Failure in Monitoring Generator Torque Performance 348 P3145 +B short in generator gate shutdown signal circuit 344 346 P3140 Generator inverter current sensor malfunction (W phase sub sensor) 335 343 P3135 Detecting Condition Generator inverter current sensor malfunction (V phase sub sensor) 342 P3130 HYBRID VEHICLE CONTROL SYSTEM 326 334 P3125 Detection Item – 351 352 Electric cooling fan system malfunction Open or +B short in circuit breaker sensor Safety devices operating with vehicle is stopped (ILK signal ON) I t l kM Interlock Malfunction lf ti Vehicle Speed Sensor Circuit Malfunction Open circuit in interlock signal circuit while vehicle is running No input of vehicle speed signal during cruise control driving DI–207 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM DI82N–02 TERMINALS OF ECU HV ECU Terminals H14 H13 H12 H11 H10 9 8 7 6 5 4 3 2 1 21 2019 1817161514 1312 11 10 3130 29 2827 262524 2322 7 6 5 4 3 2 1 16 151413 12 1110 9 8 24 2322 2120 1918 17 6 5 4 3 2 1 12 1110 9 8 7 1716 151413 9 8 7 6 5 4 3 2 1 19 18171615141312 11 10 28 2726 2524 23 222120 7 6 5 4 3 2 1 15 141312 1110 9 8 22 212019 18 17 16 A04997 A02508 Symbols (Terminals No.) Wiring Color Condition STD Voltage (V) BATT (H14–3) ↔ GND1 (H14–31) G–Y ↔ W–B Always 9 – 14 +B1 (H14–4) ↔ GND1 (H14–31) W–G ↔ W–B Ignition switch ON and ”READY” light ON 9 – 14 +B2 (H14–5) ↔ GND1 (H14–31) W–G ↔ W–B Ignition switch ON and ”READY” light ON 9 – 14 IGSW (H13–7) ↔ GND1 (H14–31) B–W ↔ W–B Ignition switch ON 9 – 14 ST2 (H13–6) ↔ GND1 (H14–31) R–W ↔ W–B Ignition switch ST 9 – 14 ST1 (H14–2) (H14 2) ↔ GND1 (H14–31) B Y ↔ W–B B–Y W B STP (H14 (H14–1) 1) ↔ GND1 (H14–31) G W ↔ W–B G–W W B Brake pedal is depressed Below 0.5 Brake pedal is released 9 – 14 Brake pedal is depressed 9 – 14 Brake pedal is released Below 0.5 Ignition switch ON Approx. 5 Ignition switch ON and accelerator pedal is released Approx. 1 Ignition switch ON and accelerator pedal is fully depressed Approx. 4 VCP1 (H14–13) ↔ GND1 (H14–31) Y ↔ W–B VPA1 (H14–14) (H14 14) ↔ GND1 (H14–31) G ↔ W–B W B EP1 (H14–12) ↔ GND1 (H14–31) L ↔ W–B Ignition switch ON Below 0.5 VCP2 (H14–23) ↔ GND1 (H14–31) B ↔ W–B Ignition switch ON Approx. 5 VPA2 (H14–15) (H14 15) ↔ GND1 (H14–31) W ↔ W–B W B Ignition switch ON and accelerator pedal is released Approx. 1 Ignition switch ON and accelerator pedal is fully depressed Approx. 4 EP2 (H14–22) ↔ GND1 (H14–31) R ↔ W–B Ignition switch ON Below 0.5 P (H13–15) (H13 15) ↔ GND1 (H14 (H14–31) 31) L R↔W L–R W–B B R (H13 (H13–14) 14) ↔ GND1 (H14–31) (H14 31) R B ↔ W–B R–B W B N (H13 (H13–13) 13) ↔ GND1 (H14–31) (H14 31) L W ↔ W–B L–W W B D (H13 (H13–23) 23) ↔ GND1 (H14–31) (H14 31) L B ↔ W–B L–B W B B (H13–22) (H13 22) ↔ GND1 (H14 (H14–31) 31) LG R ↔ W–B LG–R W B 2001 PRIUS (RM778U) Shift lever is P position Except shift lever is P position Shift lever is R position Except shift lever is R position Shift lever is N position Except shift lever is N position Shift lever is D position Except shift lever is D position Shift lever is B position Except shift lever is B position Below 1 4 or more Below 1 4 or more Below 1 4 or more Below 1 4 or more Below 1 4 or more DI–208 DIAGNOSTICS SFT (H13–11) ↔ GSFT (H13 21) (H13–21) VSFT (H13–12) ↔ GSFT (H13–21) B–R B R W–R SPDI (H12–8) ↔ GND1 (H14–31) V–W ↔ W–B ESTP (H14 (H14–8) 8) ↔ GND1 (H14–31) R Y ↔ W–B R–Y W B SPDO (H14–6) ↔ GND1 (H14–31) O ↔ W–B NODD (H12–4) ↔ GND1 (H14 31) (H14–31) ILK (H13 (H13–4) 4) ↔ GND1 (H14–31) AS1G (H12–14) ↔ AS1 (H12–15) IB (H14–25) (H14 25) ↔ GB (H14 (H14–26) 26) L–O L O↔W W–B B O ↔ W–B W B BR–B ↔ G–R B L ↔ R–W B–L R W – HYBRID VEHICLE CONTROL SYSTEM Shift lever is P position Approx. 0.5 Shift lever is R position Approx. 2.8 Shift lever is N position Approx. 3.4 Shift lever is D position Approx. 4.0 Shift lever is B position Approx. 4.5 Ignition switch ON 4 or more Ignition switch ON and rotor driving wheel slowly Engine stop is not required Engine stop is required Ignition switch ON and rotor driving wheel slowly 5–7 When converter is improper 2–4 When converter is required to stop 0.1 – 0.5 Ignition switch ON and interlock switch ON Below 1 Ignition switch ON and interlock switch OFF 4 or more Ignition switch ON 2.5 – 2.9 Ignition switch OFF Below 1 Ignition switch from ON to ST (”READY” light ON) 0.5 – 4.5 2.7 – 3.2 Ignition switch ON and ”READY” light ON MREL (H12–7) ↔ GND1 (H14–31) O ↔ W–B Ignition switch ON 9 – 14 Communication Line Wiring Color Connecting Part or Symbol (Terminal No.) GSNG (H10–11) G MG1, GSNG (M2–7) GSN (H10–4) R MG1, GSN (M2–2) GRF (H10–10) B MG1, GRF (M2–1) GRFG (H10–17) W MG1, GRFG (M2–6) GCS (H10–5) Y MG1, GCS (M2–3) GCSG (H10–12) BR MG1, GCSG (M2–8) GMTG (H10–8) G–W MG1, GMTG (M2–9) GMT (H10–1) B–R MG1, GMT (M2–4) MSNG (H10–20) G MG2, MSNG (M3–5) MSN (H10–13) R MG2, MSN (M3–2) MRF (H10–19) P MG2, MRF (M3–1) MRFG (H10–18) L MG2, MRFG (M3–4) MCS (H10–14) B MG2, MCS (M3–3) MCSG (H10–21) W MG2, MCSG (M3–6) MMTG (H10–9) R–W MG2, MMTG (M4–3) GR MG2, MMT (M3–1) MSIV (H11–21) G Inverter, M–SINV (I10–7) MSDN (H11–13) Y Inverter, M–SDOWN (I9–4) MIT (H11–11) L Inverter, M–INVT (I9–5) 2001 PRIUS (RM778U) Pulse generation When converter is in normal operation L ↔ W–B MMT (H10–2) 9 – 14 Below 1 ABFS (H13–3) ↔ GND1 (H14–31) Symbols (Terminals No.) Pulse generation DI–209 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM MWU (H11–6) G Inverter, M–WU (I9–3) MUU (H11–4) R Inverter, M–UU (I9–1) MVU (H11–5) W Inverter, M–VU (I9–2) MIVG (H11–26) B Inverter, M–GINV (I9–6) MIVA (H11–16) B Inverter, M–IVA (I10–1) MIVB (H11–7) W Inverter, M–IVB (I10–3) MIWB (H11–17) G Inverter, M–IWB (I10–4) VB (H11–20) Y Inverter, VB (I10–5) MIWA (H11–25) R Inverter, M–IWA (I10–2) GIVA (H11–19) B Inverter, G–IVA (I12–1) GIVB (H11–8) W Inverter, G–IVB (I12–3) GIWB (H11–18) G Inverter, G–IWB (I12–4) GIWA (H11–28) R Inverter, G–IWA (I12–2) GSDN (H11–12) Y Inverter, G–SDOWN (I11–4) GIT (H11–23) L Inverter, G–INVT (I11–5) GWU (H11–3) G Inverter, G–WU (I11–3) GVU (H11–2) W Inverter, G–VU (I11–2) GUU (H11–1) R Inverter, G–UU (I11–1) GIVG (H11–27) B Inverter, G–GINV (I11–6) MFIV (H11–14) B Inverter, M–FINV (I10–8) GSIV (H11–15) G Inverter, G–SINV (I12–7) GFIV (H11–24) B Inverter, G–FINV (I12–8) ETH+ (H14–28) P Engine ECU, ETH+ (E9–28) ETH– (H14–27) L Engine ECU, ETH– (E9–27) HTE+ (H14–19) Y Engine ECU, H TE+ (E9–19) HTE– (H14–29) BR Engine ECU, H TE– (E9–18) HTB+ (H14–20) LG Brake ECU, HVI+ (B10–24) HTB– (H14–30) V Brake ECU, HVI– (B10–16) BTH+ (H14–18) G Brake ECU, HVO+ (B10–14) BTH– (H14–17) R Brake ECU, HVO– (B10–22) FCVC (H14–7) B–W CON1 (H12–13) V System Main Relay (S8–3) CON2 (H12–2) GR System Main Relay (S8–4) CON3 (H13–1) P System Main Relay (S8–5) HTD+ (H13–2) W Battery ECU, HTD+ (B17–6) HTD– (H13–20) B Battery ECU, HTD– (B17–7) DTD+ (H13–19) R Battery ECU, DTD+ (B17–18) DTD– (H13–18) G Battery ECU, DTD– (B17–19) 2001 PRIUS (RM778U) Transponder Key ECU, HEVC (T4–8) DI–210 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM DI82O–02 CIRCUIT INSPECTION DTC B2799 Immobilizer Malfunction CIRCUIT DESCRIPTION The HV ECU checks the condition of the communication from the transponder key ECU. DTC B2799 – Information code 101 INF. code. 101 Detecting Condition Trouble Area
Wire harness
Immobilizer system No input of signal from transponder key ECU WIRING DIAGRAM T4 Transponder Key ECU HEVC Hybrid Vehicle Control ECU 8 B–W 7 H14 FCVC A14140 2001 PRIUS (RM778U) DI–211 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check for open and short in wire harness between HV ECU FCVC terminal and transponder key ECU HEVC terminal (See page IN–41). NG OK Check and repair immobilizer system (See page BE–104). 2001 PRIUS (RM778U) Repair or replace wire harness. DI–213 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM DI82Q–02 DTC P1120 Accelerator Pedal Position Sensor Circuit Malfunction CIRCUIT DESCRIPTION The accelerator pedal position sensor mounted on the accelerator pedal has main and sub sensors and detects the accelerator pedal position and the malfunction of the accelerator position sensor itself. HINT:
When using an OBD scan tool other than TOYOTA hand–held tester, check all the steps.
When using TOYOTA hand–held tester, confirm the information code and check it. DTC P1120 – Information code 104, 105, 107, 108 INF. code. Detecting Condition 104 Open or short in main accelerator sensor circuit 105 +B short in main accelerator sensor circuit 107 Open or short in sub accelerator sensor circuit 108 +B short in sub accelerator sensor circuit Trouble Area
Accelerator pedal edal position osition sensor
Wire harness WIRING DIAGRAM A13 Accel Position Sensor Y VCP1 6 G VPA1 5 L EP1 3 B VCP2 4 VPA2 W 2 EP2 R 1 13 H14 14 H14 12 H14 23 H14 15 H14 Hybrid Vehicle Control ECU VCP1 VPA1 EP1 VCP2 VPA2 22 H14 EP2 A14132 2001 PRIUS (RM778U) DI–214 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check for open, short and +B short in wire harness between HV ECU and accelerator pedal position sensor (See page IN–41). Terminals for checking open and short: Accelerator pedal position sensor Terminals HV ECU Terminals VCP1 VCP1 VPA1 VPA1 EP1 EP1 VCP2 VCP2 VPA2 VPA2 EP2 EP2 HINT: The acceleration pedal position sensor circuit has +B short if the voltage at the HV ECU VPA1 or VPA2 terminal is more than 5V with the ignition ON. NG Repair or replace wire harness. OK Check and replace accelerator pedal position sensor (See page SF–59). DTC P1120 – Information code 106, 109, 110, 111, 112, 113, 114 INF. code. Detecting Condition 106 Main sensor internal error 109 Sub sensor internal error 110 When difference between main sensor value and sub sensor value is large 111 When sub sensor value changes while main sensor value does not 112 When main sensor value changes while sub sensor value does not 113 When any of the information code 104 – 112 continues to appear 114 Accelerator pedal not smoothly returning to original position Trouble Area
Accelerator pedal edal position osition sensor INSPECTION PROCEDURE If the information code 106 or 109 – 114 is output,check and replace the accelerator pedal position sensor (See page SF–59). 2001 PRIUS (RM778U) DI–215 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM DI82R–02 DTC P1520 Stop Light Switch (Cruise Control System) Malfunction CIRCUIT DESCRIPTION The HV ECU detects the malfunction of the cruise control system and inhibits the operation of the cruise control. It detects faulty output of the STP and ST1– signals sent from the stop light switch or an error signal from the brake ECU. DTC P1520 – Information code 115 INF. code. Detecting Condition 115 Trouble Area
Stop light switch
Wire harness
Brake ECU Open or short in stop light switch circuit WIRING DIAGRAM S3 Stop Light SW 2 J/C B–W I15 Ignition SW IG2 AM2 6 B J25 B–W 6 ID1 R–B B–W 3 9 2K 2 H14 ST1– 4 Engine Room J/B AM2 9 1 W–R 2G 1J STOP D 1 G–W J15 H14 STP B–Y Instrument Panel J/B 2 W–R 2C 7 J/C E G–W J14 1 R–B B J24 Hybrid Vehicle Control ECU 2 1B B 1 2H Fusible Link Block No. 1 1 MAIN F18 W F11 1 B–G 1 F13 F12 1 DC/DC Fusible Link Block No. 1 Battery A14147 2001 PRIUS (RM778U) DI–216 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Is DTC of brake ECU being output? YES Check DTC of brake ECU (See page DI–358). NO 2 Check voltage between terminal 2, 3 of stop light switch and body ground. NG Repair or replace wire harness or connector. OK 3 Check for open and short in wire harness between stop light switch and terminals STP, ST1– of HV ECU (See page IN–41). NG Repair or replace wire harness. OK Check and replace stop light switch (See page BE–32). 2001 PRIUS (RM778U) DI–217 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM DI82S–02 DTC P1566 Cruise Control System Malfunction CIRCUIT DESCRIPTION The HV ECU and the brake ECU monitor the same STP signal. If any difference is identified between both received signals, the HV ECU outputs an error. DTC P1566 – Information code 116 INF. code. Detecting Condition Trouble Area 116 When STP signal of HV ECU is inconsistent with that of brake ECU, with cruise control indicator ON.
Brake ECU
Wire harness
Stop light switch WIRING DIAGRAM Refer to DI–215. INSPECTION PROCEDURE 1 Is DTC of brake ECU being output (See page DI–351)? YES Check DTC of brake ECU (See page DI–351 ). NO 2 Check for +B short in wire harness between stop light switch and terminals STP, ST1–of HV ECU (See page IN–41). HINT: Under the normal condition, the voltage of the HV ECU STP terminal is 0V when the brake pedal is released with the ignition OFF. If there is any output of voltage at this time, the stop light switch circuit has +B short. NG OK 2001 PRIUS (RM778U) Repair or replace wire harness. DI–218 DIAGNOSTICS 3 – HYBRID VEHICLE CONTROL SYSTEM Check for open and short in wire harness between stop light switch and brake ECU. NG Repair or replace wire harness. OK Check and replace stop light switch (See page BE–32). 2001 PRIUS (RM778U) DI–219 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM DI82T–02 DTC P1600 BATT Malfunction CIRCUIT DESCRIPTION Since the ECU back–up power source is used for DTC and freeze frame data memory, the back–up power source (BATT) continues to be supplied to the HV ECU even though the ignition switch is turned OFF. DTC P1600 – Information code 117 INF. code. 117 Detecting Condition Trouble Area
HV Fuse
Wire harness HV ECU back–up power source circuit malfunction WIRING DIAGRAM B J2 G–Y J/C Hybrid Vehicle Control ECU B J3 4 IA1 G–Y Engine Room J/B 11 1F HV 1 1B B G–Y 3 H14 BATT Fusible Link Block No. 1 1 1 F13 F12 Fusible Link Block No. 2 1 MAIN F18 B–G Battery A14146 2001 PRIUS (RM778U) DI–220 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check continuity of HV fuse of engine room J/B. OK: Continuity NG OK Repair or replace wire harness. 2001 PRIUS (RM778U) Check for short in all harness and parts connected to HV fuse. DI–221 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM DI82U–02 DTC P1780 Park/neutral Position Switch System Malfunction CIRCUIT DESCRIPTION The park/neutral position switch sends both main sensor signal (switch signal) and sub sensor signal (analogue value) to the HV ECU. The HV ECU uses those signals to detect the shift lever position (P, R, N, D or B) and to control the forward and backward movement of the vehicle. HINT:
When using an OBD scan tool other than TOYOTA hand–held tester, check all the steps.
When using TOYOTA hand–held tester, confirm the information code and check it. DTC P1780 – Information code 118, 119, 120, 121 INF. code. Detecting Condition Trouble Area 118 When more than 2 main signals are ON 119 When main signal is not turned ON even though sub signal has been input 120 Open or short in sub sensor circuit 121 When shift position detected by main signal is different from that detected by sub signal
Park/neutral position osition switch
Wire harness WIRING DIAGRAM Hybrid Vehicle Control ECU P1 Park/neutral Position SW L–R 15 H13 P L–W 13 H13 N L–B 23 H13 D LG–R 22 H13 B R–B 14 H13 R 2 5 6 7 4 W 12 H13 VSFT B 11 H13 SFT R 21 H13 FSFT 9 8 3 A14130 2001 PRIUS (RM778U) DI–222 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check for open and short in wire harness between park/neutral position switch and HV ECU (See page IN–41). Terminals for checking open and short: Park/neutral Position Switch Terminals HV ECU Terminals 2 P 5 N 6 D 7 B 4 R 9 VSFT 8 SFT 3 GSFT NG Repair or replace wire harness. OK Check and repair park/neutral position switch (See page HT–54). 2001 PRIUS (RM778U) DI–225 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM DI82X–02 DTC P3004 Power Cable Malfunction CIRCUIT DESCRIPTION If the inverter voltage is not decreased after discharge with the ignition switch OFF, the VM sensor in the inverter is determined as defective. HINT:
When using an OBD scan tool other than TOYOTA hand–held tester, check all the steps.
When using TOYOTA hand–held tester, confirm the information code and check it. DTC P3004 – Information code 130 INF. Code. Detecting Condition Trouble Area 130 When HV battery voltage becomes lower than inverter voltage Converter & inverter assembly INSPECTION PROCEDURE 1 Are there any other codes of HV ECU being outputs? YES NO Replace converter & inverter assembly. 2001 PRIUS (RM778U) Go to relevant DTC chart. DI–226 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM DTC P3004 – Information code 131 INF. Code. 131 Detecting Condition Trouble Area When condition (a), (b) or (c) is detected: (d) Main fuse blown out (e) Service plug disconnected (f) Limiter resistance cut off
Service plug
Power cable
System main relay INSPECTION PROCEDURE 1 Is DTC of battery ECU being output? YES Check the applicable DTC. NO 2 Check condition of service plug terminal (Loosened, poor contact, etc.). NG Replace service plug. OK 3 Check continuity of power cable. OK: Continuity :Less than 1 Ω NG OK Replace the system main relay. 2001 PRIUS (RM778U) Replace the power cable. DI–227 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION DTC P3004 – Information code 132 INF. Code. Detecting Condition Trouble Area 132 When inverter voltage sensor is malfunctioning or limiter resistance value increases.
Converter & inverter assembly
Power cable
System main relay INSPECTION PROCEDURE 1 Are other information codes recorded? YES Check applicable information code (See page DI–197). NO 2 Check continuity of limiter resistance in system main relay. PREPARATION: Remove the system main relay. CHECK: (a) Apply battery voltage across terminals 1 and 3. (b) Using an ohmmeter, check that there is continuity between terminals A and B. OK: Continuity A B A15179 NG OK Check continuity and replace power cable. 2001 PRIUS (RM778U) Replace the system main relay. DI–228 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU gives warning to the driver and performs the fail safe control, according to the abnormal signal received from the battery ECU. DTC P3004 – Information code 133 INF. Code. 133 Detecting Condition Input of abnormal signal from battery ECU Trouble Area
HV battery system INSPECTION PROCEDURE If the information code 133 output, after confirming the DTC of the HV Battery ECU, check and repair the applicable DTC. After repairing it, record the DTC of the HV ECU, freeze frame data and history of operation. Then, clear the DTC and check it one more time after starting the system again (”READY” light ON). 2001 PRIUS (RM778U) DI–229 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM DI82Y–02 DTC P3100 HV ECU Malfunction CIRCUIT DESCRIPTION The HV ECU compares Ne signal with G signal that are sent from the ECM and checks whether the engine rpm signal is correct or not. HINT:
When using an OBD scan tool other than TOYOTA hand–held tester, check all the steps.
When using TOYOTA hand–held tester, confirm the information code and check it. DTC P3100 – Information code 136, 137 INF. Code. Detecting Condition 136 Open or short in GO signal circuit 137 Engine speed sensor malfunction Trouble Area
Wire harness
ECM
Crankshaft position sensor
Camshaft position sensor WIRING DIAGRAM Hybrid Vehicle Control ECU ECM GO 21 E9 G 9 IA2 G 10 H12 GO A14150 2001 PRIUS (RM778U) DI–230 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Is DTC of ECM being output (See page DI–1)? Yes Check applicable DTC (See page DI–1). NO 2 Check for open and short in wire harness between GO terminal of HV ECU and GO terminal of ECM (See page IN–41). NG Repair or replace wire harness. OK 3 Check resistance of crankshaft position sensor and camshaft position sensor (See page IG–1). NG OK Replace ECM. 2001 PRIUS (RM778U) Replace the crankshaft position sensor or camshaft position sensor. DI–231 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU checks the current value of the battery and detects malfunction. DTC P3100 – Information code 127, 128, 138 INF. Code. Detecting Condition Trouble Area 127 +B short in IB terminal circuit of HV ECU 128 Open or short in IB terminal circuit of HV ECU 138 When the difference between battery current of HV ECU and current of battery is large.
Wire harness
HV ECU WIRING DIAGRAM Hybrid Vehicle Control ECU Battery ECU 16 IB B17 B–L 6 IB1 B–L 25 H14 IB 17 GB B17 R–W 10 IB1 R–W 26 H14 GB A15650 2001 PRIUS (RM778U) DI–232 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Is DTC of battery ECU being output (See page DI–312)? HINT: In case of output of Information code 128, check whether V– wire harness of battery ECU DTC P3115 is open or short at first. When there is no–abnormality, go to step 2. Yes Check applicable DTC (See page DI–312). NO 2 Check for open, short and +B short in wire harness between HV ECU IB and GB terminals and battery ECU IB and GB terminals (See page IN–41). HINT: The HV ECU IB terminal has +B short if there is no open in wire harness and the voltage of the IB or GB terminal is more than 5 V with the ignition ON. NG OK Replace HV ECU. 2001 PRIUS (RM778U) Repair or replace wire harness. DI–233 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU checks the ST signal and detects malfunction. If the ST signal has +B short, the ST will always be ON. Therefore, even with the IG ON when starting the THS, the system will start. To prevent this from happening, the HV ECU detects the malfunction of the ST signal. DTC P3100 – Information code 142 INF. Code. Detecting Condition Trouble Area When ST signal of HV ECU is ON, with ignition switch turned OFF. 142
Wire harness
HV ECU
Ignition switch WIRING DIAGRAM Instrument Panel J/B W–R 2 2 2G 2C W–R R–W 7 Engine Room J/B 9 AM2 1J 2 1B Fusible Link Block No. 2 1 MAIN F18 B Hybrid Vehicle Control ECU I15 Ignition SW AM2 ST2 6 H13 ST2 8 Fusible Link Block No. 1 1 1 F12 F13 B–G B–G Battery A14148 2001 PRIUS (RM778U) DI–234 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check ignition switch (See page BE–17). NG Replace ignition switch (See page SR–11). NO 2 Check for +B short in wire harness between ignition switch ST2 terminal and HV ECU ST2 terminal (See page IN–41). HINT: The HV ECU ST circuit has +B short if battery voltage is supplied to the ST2 terminal. NG OK Replace HV ECU. 2001 PRIUS (RM778U) Repair or replace wire harness. DI–235 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU checks the internal operation of the ECU and detects malfunction. DTC P3100 – Information code 134, 135, 139, 140, 141, 143, 144, 145, 146, 147, 148, 149, 150, 151, 152, 153, 154, 155, 156, 157, 158, 159, 160, 161, 162, 163, 164, 165, 166, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 177, 178, 179, 180, 181, 182, 183, 184, 185, 186, 187, 188, 189, 190, 191, 192, 193, 194, 195, 196, 197, 198, 199, 200, 201, 202, 203, 271, 310, 390, 391, 392, 393 INF. Code. 134 Detecting Condition HV ECU internal error 135 139 140 141 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 2001 PRIUS (RM778U) Trouble Area
HV ECU DI–236 DIAGNOSTICS INF. Code. 170 – HYBRID VEHICLE CONTROL SYSTEM Detecting Condition HV ECU internal error Trouble Area
HV ECU 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 271 310 390 391 392 393 INSPECTION PROCEDURE If any of the above information codes is output, replace the HV ECU. 2001 PRIUS (RM778U) DI–238 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM DI830–02 DTC P3105 Battery ECU Communication Circuit Malfunction CIRCUIT DESCRIPTION The HV ECU monitors the communication signal from the battery ECU and if it cannot monitor it due to noise or other reasons, judges as an error. DTC P3105 – Information code 206, 207, 208 INF. Code. Detecting Condition Trouble Area 206 207 When communication between battery ECU and HV ECU is abnormal 1 sec. sec after ignition is turned ON
Wire harness
Battery ECU 208 WIRING DIAGRAM Battery ECU BEH+ 18 B17 R 4 IF2 R G 3 IF2 G 19 BEH– B17 Hybrid Vehicle Control ECU 19 H13 DTH+ 18 H13 DTH– A14734 2001 PRIUS (RM778U) DI–239 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check for open and short in wire harness between HV ECU terminals (DTH+, DTH–) and battery ECU terminals (BEH+, BEH–) (See page IN–41). NG OK Replace battery ECU. 2001 PRIUS (RM778U) Repair or replace wire harness. DI–240 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM DI831–02 DTC P3106 ECM Communication Circuit Malfunction CIRCUIT DESCRIPTION The HV ECU monitors the communication signal from the ECM and if it cannot monitor it due to noise or other reasons, judges as an error. HINT:
When using an OBD scan tool other than TOYOTA hand–held tester, check all the steps.
When using TOYOTA hand–held tester, confirm the information code and check it. DTC P3106 – Information code 209, 210, 211 INF. Code. Detecting Condition Trouble Area 209 210 When communication between ECM and HV ECU is abnormal 1 sec. sec after ignition is turned ON
Wire harness
ECM 211 WIRING DIAGRAM Hybrid Vehicle Control ECU ECM ETH+ 28 E9 27 ETH– E9 P L 28 H14 ETH+ 27 H14 ETH– A14738 2001 PRIUS (RM778U) DI–241 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check for open and short in wire harness between HV ECU terminals (ETH+, ETH–) and ECM terminals (ETH+, ETH–) (See page IN–41). NG Repair or replace wire harness. OK Replace ECM. CIRCUIT DESCRIPTION DTC P3106 – Information code 212 INF. Code. 212 Detecting Condition Input of abnormal signal from ECM Trouble Area
ECM INSPECTION PROCEDURE If the information code 212 is output, after confirming the DTC of the ECM, check and repair the applicable DTC. Prior to repairing it, record the DTC of the HV ECU, freeze frame data and history of operation. Then, clear the DTC and check it one more time after starting the system again (”READY” light ON). CIRCUIT DESCRIPTION DTC P3106 – Information code 394 INF. Code. 394 Detecting Condition When ECM does not operate Trouble Area
ECM INSPECTION PROCEDURE If the information code 394 is output, check and repair the ECM power source circuit. If there is no problem in the power source circuit, replace the ECM. Prior to the repair, record the DTC of the HV ECU, freeze frame data and history of operation and clear them. Then, start the system one more time (”READY” light ON) and check the DTC again. 2001 PRIUS (RM778U) DI–242 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM DI832–02 DTC P3107 Airbag ECU Communication Circuit Malfunction CIRCUIT DESCRIPTION The HV ECU detects the malfunction of the collision signal circuit from the airbag and gives warning to the driver. DTC P3107 – Information code 213, 214, 215 INF. Code. Detecting Condition Trouble Area 213 214 When communication between airbag ECU and HV ECU is abnormal 10 sec sec. after ignition is turned ON
Wire harness
Airbag sensor assembly 215 WIRING DIAGRAM Hybrid Vehicle Control ECU Airbag Sensor Assembly 23 GSW2 A18 L 3 H13 ABFS A14139 2001 PRIUS (RM778U) DI–243 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check for open, short and +B short in wire harness between HV ECU ABFS terminals and airbag ECU GSW 2 terminal (See page IN–41). HINT: Confirm that there is no open circuit in the wire harness. If the battery voltage is always applied to the HV ECU ABFS terminal with the ignition ON, the airbag signal circuit has +B short. NG OK Replace airbag sensor assembly. 2001 PRIUS (RM778U) Repair or replace wire harness. DI–245 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM DI834–02 DTC P3109 Brake ECU Communication Circuit Malfunction CIRCUIT DESCRIPTION The HV ECU performs multiple checks to avoid any malfunction that may occur through the communication with the brake ECU due to a noise, etc. HINT:
When using an OBD scan tool other than TOYOTA hand–held tester, check all the steps.
When using TOYOTA hand–held tester, confirm the information code and check it. DTC P3109 – Information code 218, 219, 220, 221 INF. Code. Detecting Condition Trouble Area 218 219 220 When communication between brake ECU and HV ECU is abnormal b l 1.5 1 5 sec. after ft ignition i iti is i turned t d ON
Wire harness
Brake ECU 221 WIRING DIAGRAM Hybrid Vehicle Control ECU Brake ECU HV1+ 24 B11 LG HV1– 16 B11 V 14 G HVO– B11 30 H14 HTB– HVO+ B11 22 20 H14 HTB+ 18 H14 BTH+ R 17 H14 BTH– A14137 2001 PRIUS (RM778U) DI–246 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check for open, short and +B short in wire harness between HV ECU terminals (HTB+, HTB–, BTH+, BTH–) and brake ECU terminals (HV1+, HV1–, HVO+, HVO–) (See page IN–41). HINT: Confirm that there is no open circuit in the wire harness. If the voltage of each HV ECU terminals (HTB+, HTB–, BTH+ and BTH–) is always more than 5 V with the ignition ON, the brake ECU communication circuit has +B short. NG Repair or replace wire harness. OK Replace brake ECU. CIRCUIT DESCRIPTION DTC P3109 – Information code 222 INF. Code. 222 Detecting Condition When abnormal data is received from brake ECU. Trouble Area
Brake ECU INSPECTION PROCEDURE If the information code 222 is output, after confirming the DTC of the brake ECU, check and repair the applicable DTC. Prior to repairing it, record the DTC of the HV ECU, freeze frame data and history of operation. Then, clear the DTC and check it one more time after starting the system again (”READY” light ON). 2001 PRIUS (RM778U) DI–247 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM DI835–02 DTC P3110 IGCT Relay Malfunction CIRCUIT DESCRIPTION The HV ECU checks the IGCT relay and detects malfunction. DTC P3110 – Information code 223 INF. Code. Detecting Condition Trouble Area When IGCT relay is always closed.
Wire harness
IGCT relay 223 WIRING DIAGRAM Hybrid Vehicle Control ECU Engine Room R/B No. 2 IGCT Relay G–Y 2 1F 11 Engine Room J/B 3 2 W–G 7 H12 MREL O 2 1 4 H14 +B1 2 W–B HV J1 J/C A 1B 1 B 2 5 12 IA1 W–G J7 J/C W–B A Fusible Link Block No. 1 F12 F13 B–G A Fusible Link Block No. 2 1 F18 A MAIN W–B Battery IE EC A14737 2001 PRIUS (RM778U) DI–248 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check IGCT relay. Continuity Ohmmeter 2 Ohmmeter 1 5 3 No Continuity 2 1 Ohmmeter 5 Battery PREPARATION: Remove the IGCT relay from the engine room R/B No. 3. CHECK: (a) Using an ohmmeter, check that there is continuity between terminals 1 and 2. (b) Check that there is no continuity between terminals 3 and 5. (c) Apply battery voltage across terminals 1 and 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. OK: (a) Continuity (b) No continuity (c) Continuity 3 Continuity S04947 NG Replace IGCT relay. S04946 A14712 OK Check for +B short in wire harness between HV ECU and IGCT relay (See page IN–41). Repair or replace wire harness. HINT: The HV ECU MREL terminal has +B short if the battery voltage is always applied to the HV ECU +B1 or MREL terminal with the ignition OFF. 2001 PRIUS (RM778U) DI–249 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM DI836–02 DTC P3115 System Main Relay Malfunction CIRCUIT DESCRIPTION The HV ECU checks that the system main relay (No. 1, No. 2, No. 3) is normally operating and detects malfunction. HINT:
When using an OBD scan tool other than TOYOTA hand–held tester, check all the steps.
When using TOYOTA hand–held tester, confirm the information code and check it. DTC P3115 – Information code 224, 225, 226, 227, 228, 229 INF. Code. Detecting Condition Trouble Area 224 Open or +B short in system main relay No. 1 circuit 225 Short in system main relay No. 1 circuit 226 Open or +B short in system main relay No. 2 circuit 227 Short in system main relay No. 2 circuit 228 Open or +B short in system main relay No. 3 circuit 229 Short in system main relay No. 3 circuit
Wire harness
System S t main i relay l
HV ECU WIRING DIAGRAM System Main Relay 3 S8 Hybrid Vehicle Control ECU V 8 IH1 V 4 S8 GR 9 IH1 GR 5 S8 P 11 IF1 P 13 H12 CON1 2 H12 CON2 1 H13 CON3 A14143 2001 PRIUS (RM778U) DI–250 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check for open, short and +B short in wire harness between HV ECU terminals (Cont1, Cont2, Cont3) and system main relay terminals (See page IN–41). HINT: Confirm that there is no open circuit in the wire harness. If the battery voltage is always applied to the HV ECU Cont1, Cont2 and Cont3 terminals with the ignition ON (”READY” light OFF), the system main relay has +B short. NG Repair or replace wire harness. OK 2 Is any of the information code 231, 232 or 233 recorded? NO YES Replace HV ECU and system main relay. 2001 PRIUS (RM778U) Replace HV ECU. DI–251 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION If the system main relay is deposited, it might be impossible to shut down the high voltage system. Therefore, the HV ECU checks the system main relay and stops the system if malfunction is detected. DTC P3115 – Information code 231, 232, 233 INF. Code. Detecting Condition 231 System main relay + terminal deposited 232 System main relay – terminal deposited 233 System main relay + & – terminal deposited Trouble Area
System main relay
HV ECU INSPECTION PROCEDURE If any of these information codes is output, replace the system main relay. If one of the information codes above and any of the information codes 224 – 229 are recorded at the same time, also replace the HV ECU. 2001 PRIUS (RM778U) DI–252 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM DI837–02 DTC P3120 HV Transaxle Malfunction CIRCUIT DESCRIPTION The HV ECU checks the energy balance and detects abnormality if the magnetism of the motor or generator greatly decreases. HINT:
When using an OBD scan tool other than TOYOTA hand–held tester, check all the steps.
When using TOYOTA hand–held tester, confirm the information code and check it. DTC P3120 – Information code 234, 235, 236, 237 INF. Code. Detecting Condition 234 Small reduction of motor magnetism 235 Large reduction of motor magnetism 236 Small reduction of generator magnetism 237 Large reduction of generator magnetism Trouble Area
HV transaxle (motor)
System main relay
HV transaxle (generator)
System main relay INSPECTION PROCEDURE 1 Is DTC of HV battery ECU being output? YES Check applicable DTC. NO 2 Turn the ignition switch to ST(ON) and check if malfunction occurs again. NO YES Replace HV transaxle motor or generator. 2001 PRIUS (RM778U) Replace system main relay. DI–253 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU detects the malfunction of the transmission system. Judging from a malfunction symptom, it records one of the four information codes. DTC P3120 – Information code 239, 240, 241, 242 INF. Code. Detecting Condition 239 Shaft damaged 240 Generator locked 241 Torque limiter sliding 242 Planetary gear locked Trouble Area
HV transaxle t l INSPECTION PROCEDURE When Information code 239 in stored, check that the connector of the crankshaft position sensor is properly connected. If disconnected, the code 239 may be stored. If any of these information codes is output, replace the defective part inside the HV transaxle. 2001 PRIUS (RM778U) DI–254 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU checks the motor resolver signal voltage and circuit impedance to detect malfunction. DTC P3120 – Information code 243, 245 INF. Code. Detecting Condition 243 Motor resolver inter–phase short 245 Open or short in motor resolver circuit Trouble Area
HV transaxle
Wire harness WIRING DIAGRAM Hybrid Vehicle Control ECU Motor Generator No. 2 5 MSNG M3 2 MSN M3 3 MCS M3 6 MCSG M3 1 M3 MRF 4 MRFG M3 G R P L B W 20 H10 MSNG 13 H10 MSN 14 H10 MCS 21 H10 MCSG 19 H10 MRF 18 H10 MRFG A14122 2001 PRIUS (RM778U) DI–255 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check for open and short in wire harness between HV transaxle and HV ECU (See page IN–41). Terminals for checking open and short: MG2 Terminals HV ECU Terminals MSNG MSNG MSN MSN MCS MCS MCSG MCSG MRF MRF MRFG MRFG NG Repair or replace wire harness. OK Check for open in motor resolver or inter–phase short and then replace HV transaxle motor. Check motor resolver (See page HV–40). 2001 PRIUS (RM778U) DI–256 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU checks the motor resolver signal voltage and circuit impedance to detect malfunction. DTC P3120 – Information code 244, 246 INF. Code. Detecting Condition Trouble Area 244 Motor resolver inter–phase short (when there is a history that the state of malfunction continued during inverter fail safe mode) 246 Open or short in motor resolver circuit (when there is a history that the state of malfunction continued during inverter fail safe mode)
HV transaxle
Wire harness WIRING DIAGRAM Hybrid Vehicle Control ECU Motor Generator No. 2 5 MSNG M3 2 MSN M3 3 MCS M3 6 MCSG M3 1 M3 MRF 4 MRFG M3 G R P L B W 20 H10 MSNG 13 H10 MSN 14 H10 MCS 21 H10 MCSG 19 H10 MRF 18 H10 MRFG A14122 2001 PRIUS (RM778U) DI–257 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check for open and short in wire harness between HV transaxle and HV ECU (See page IN–41). Terminals for checking open and short: MG2 Terminals HV ECU Terminals MSNG MSNG MSN MSN MCS MCS MCSG MCSG MRF MRF MRFG MRFG NG Repair or replace wire harness. OK 2 Is there DTC P3100 being output? YES Check applicable DTC. NO 3 Is there DTC P3125 being output? YES NO Replace HV transaxle motor. 2001 PRIUS (RM778U) Check applicable DTC. DI–258 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU checks the motor temperature and controls the load limitation in order to prevent the motor from overheating. Also, it detects the abnormality of the line connection of the motor temperature sensor and malfunction of the sensor itself. DTC P3120 – Information code 247, 249 INF. Code. Detecting Condition Trouble Area 247 GND short in motor temperature sensor 249 Open or +B short in motor temperature sensor
HV transaxle
Wire harness WIRING DIAGRAM Hybrid Vehicle Control ECU Motor Generator No. 2 3 MMTG M4 1 M4 MMT R–W GR 9 H10 MMTG 2 H10 MMT A14121 2001 PRIUS (RM778U) DI–259 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check open, short and +B short in wire harness between HV transaxle motor temperature sensor MMT and MMTG terminals and HV ECU MMT and MMTG terminals (See page IN–41). HINT: Confirm that there is no open circuit in the wire harness. If the voltage of the HV ECU MMT terminal is always more than 5V with the ignition ON, the motor temperature sensor circuit has +B short. NG Repair or replace wire harness. OK Check for open in motor temperature sensor and then replace HV transaxle motor. Check motor temperature sensor (See page HV–40). CIRCUIT DESCRIPTION DTC P3120 – Information code 248, 250 INF. Code. Detecting Condition 248 Motor temperature sensor malfunction 250 Motor temperature sensor performance problem Trouble Area
HV transaxle t l motor t INSPECTION PROCEDURE If the information code 248 or 250 is output, replace the HV transaxle motor. 2001 PRIUS (RM778U) DI–260 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU checks the generator resolver signal voltage and circuit impedance to detect malfunction. DTC P3120 – Information code 253, 255 INF. Code. Detecting Condition 253 Generator resolver inter–phase short 255 Open or short in generator resolver circuit Trouble Area
HV transaxle (generator)
Wire harness WIRING DIAGRAM Hybrid Vehicle Control ECU Motor Generator No. 1 7 GSNG M2 2 M2 1 GRF M2 G R GSN 6 GRFG M2 3 GCS M2 8 GCSG M2 B W Y BR 11 H10 GSNG 4 H10 GSN 10 H10 GRF 17 H10 GRFG 5 H10 GCS 12 H10 GCSG A14122 2001 PRIUS (RM778U) DI–261 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check for open and short in wire harness between HV transaxle and HV ECU (See page IN–41). Terminals for checking open and short: MG1 Terminals HV ECU Terminals GSNG GSNG GSN GSN GCS GCS GCSG GCSG GRF GRF GRFG GRFG NG Repair or replace wire harness. OK Check for open in generator resolver or inter–phase short and then replace HV transaxle generator. Check generator resolver (See page HV–40). 2001 PRIUS (RM778U) DI–262 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU checks the generator resolver signal voltage and circuit impedance to detect malfunction. DTC P3120 – Information code 254, 256 INF. Code. Detecting Condition Trouble Area 254 Generator resolver inter–phase short (when there is a history that the state of malfunction continued during inverter fail safe mode) 256 Open or short in generator resolver circuit (when there is a history that the state of malfunction continued during inverter fail safe mode)
HV transaxle (generator)
Wire harness WIRING DIAGRAM Hybrid Vehicle Control ECU Motor Generator No. 1 7 GSNG M2 2 M2 1 GRF M2 G R GSN 6 GRFG M2 3 GCS M2 8 GCSG M2 B W Y BR 11 H10 GSNG 4 H10 GSN 10 H10 GRF 17 H10 GRFG 5 H10 GCS 12 H10 GCSG A14122 2001 PRIUS (RM778U) DI–263 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check for open and short in wire harness between HV transaxle and HV ECU (See page IN–41). Terminals for checking open and short: MG2 Terminals HV ECU Terminals MSNG MSNG MSN MSN MCS MCS MCSG MCSG MRF MRF MRFG MRFG NG Repair or replace wire harness. OK 2 Is there DTC P3100 being output? YES Check applicable DTC. NO 3 Is there DTC P3125 being output? YES NO Replace HV transaxle generator. 2001 PRIUS (RM778U) Check applicable DTC. DI–264 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU checks the generator temperature and controls the load limitation in order to prevent the generator from overheating. Also, it detects the abnormality of the line connection of the generator temperature sensor and the malfunction of the sensor itself. DTC P3120 – Information code 257, 259 INF. Code. Detecting Condition Trouble Area 257 GND short in generator temperature sensor 259 Open or +B short in generator temperature sensor
HV transaxle
Wire harness WIRING DIAGRAM Hybrid Vehicle Control ECU Motor Generator No. 1 4 GMT M2 9 GMTG M2 B–R G–W 1 H10 GMT 8 H10 GMTG A14121 2001 PRIUS (RM778U) DI–265 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check for open, short and +B short in wire harness between HV transaxle generator temperature sensor GMT and GMTG terminals and HV ECU GMT and GMTG terminals (See page IN–41). HINT: Confirm that there is no open circuit in the wire harness. If the voltage of the HV ECU GMT terminal is always more than 5V with the ignition ON, the generator temperature sensor circuit has +B short. NG Repair or replace wire harness. OK Check for open in generator temperature sensor and then replace HV transaxle generator. Check generator temperature sensor (See page HV–40). CIRCUIT DESCRIPTION DTC P3120 – Information code 258, 260 INF. Code. Detecting Condition 258 Generator temperature sensor malfunction 260 Generator temperature sensor performance problem Trouble Area
HV transaxle t l (generator) ( t ) INSPECTION PROCEDURE If the information code 258 or 260 is output, replace the HV transaxle generator. 2001 PRIUS (RM778U) DI–266 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM DI838–02 DTC P3125 Converter & Inverter Assembly Malfunction CIRCUIT DESCRIPTION If driving the vehicle with the DCDC converter malfunctioning, the voltage of the auxiliary battery will drop, which will make it impossible to keep driving the vehicle. Therefore, HV ECU checks the operation of the DCDC converter and gives warning to the driver if malfunction is detected. HINT:
When using an OBD scan tool other than TOYOTA hand–held tester, check all the steps.
When using TOYOTA hand–held tester, confirm the information code and check it. DTC P3125 – Information code 263, 264, 265 INF. Code. Detecting Condition Trouble Area 263 +B short in DCDC converter NODD wiring 264 DCDC converter malfunction 265 Open or GND short in DCDC converter NODD wiring
Converter & inverter assembly
Wire harness WIRING DIAGRAM Hybrid Vehicle Control ECU C4 Converter L–O NODD 4 4 H12 NODD A14140 2001 PRIUS (RM778U) DI–267 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check for open, short and +B short in wire harness between HV ECU NODD terminal and converter & inverter NODD terminal (See page IN–41). HINT: The converter has +B short if the battery voltage is always applied to the HV ECU NODD terminal with the ignition ON. NG OK Replace converter & inverter assembly. 2001 PRIUS (RM778U) Repair or replace wire harness. DI–268 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU checks the inverter voltage and detects malfunction. DTC P3125 – Information code 266, 267, 268, 269, 270 INF. Code. Detecting Condition Trouble Area 266 Open or GND short in inverter voltage signal circuit 267 +B short in inverter voltage signal circuit 268 Inverter voltage signal is inconsistent with battery voltage 269 Inverter voltage sensor malfunction 270 Abnormality of line connection of inverter voltage signal circuit (when there is a history that the state of malfunction continued during inverter fail safe mode)
Converter & inverter assembly
Wire harness WIRING DIAGRAM Hybrid Vehicle Control ECU Inverter VB 5 I10 6 M–GINV I9 Y B 20 H11 VB 26 H11 MIVG A14121 2001 PRIUS (RM778U) DI–269 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check for open, short and +B short in wire harness between HV ECU VB and MIVG terminals and converter & inverter assembly VB and M–GINV terminal (See page IN–41). HINT: Confirm that there is no open circuit in the wire harness. If the voltage between the HV ECU VB or MIVG terminal and body ground is always more than 5V with the ignition ON, the inverter voltage signal circuit has +B short. NG Repair or replace wire harness. OK 2 Is there DTC P3100 being output? YES NO Replace converter & inverter assembly. 2001 PRIUS (RM778U) Check applicable DTC. DI–270 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU detects faulty line connection inside the inverter. DTC P3125 – Information code 272 INF. Code. 272 Detecting Condition Trouble Area Abnormality of line connection of motor PWM (when there is a history that the state of malfunction continued during inverter fail safe mode)
Wire harness
Converter & inverter assembly WIRING DIAGRAM Hybrid Vehicle Control ECU Inverter 3 M–WU I9 1 M–UU I9 2 M–VU I9 G R W 6 H11 MWU 4 H11 MUU 5 H11 MVU A14124 2001 PRIUS (RM778U) DI–271 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check open and short in wire harness between HV ECU terminals (MUU, MVU, MWU) and inverter terminals. NG Repair or replace wire harness. OK 2 Is there DTC P3100 being output? YES NO Replace converter & inverter assembly. 2001 PRIUS (RM778U) Check applicable DTC. DI–272 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU detects faulty line connection inside the inverter. DTC P3125 – Information code 273 INF. Code. 273 Detecting Condition Trouble Area
Converter & inverter assembly
Wire harness Motor inverter malfunction WIRING DIAGRAM Hybrid Vehicle Control ECU Inverter 4 M–SDOWN I9 Y 13 H11 MSDN A14120 INSPECTION PROCEDURE 1 Check for open and short in wire harness between HV ECU MSDN terminal and converter & inverter M–SDOWN terminal. NG OK Replace converter & inverter assembly. 2001 PRIUS (RM778U) Repair or replace wire harness. DI–273 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU checks the inverter temperature and controls the load limitation in order to prevent the inverter from overheating. Also, it detects the abnormality of the line connection of the inverter temperature sensor and the malfunction of the sensor itself. DTC P3125 – Information code 274, 275, 276, 277 INF. Code. Detecting Condition Trouble Area 274 Open or +B short in motor inverter temperature sensor 275 GND short in motor inverter temperature sensor 276 Motor inverter temperature sensor malfunction 277 Motor inverter temperature sensor performance problem
Converter & inverter assembly
Wire harness WIRING DIAGRAM Hybrid Vehicle Control ECU Inverter 7 M–SINV I10 M–GINV 6 I9 G B 21 H11 MSIV 26 H11 MIVG A14121 2001 PRIUS (RM778U) DI–274 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check for open, short and +B short in wire harness between HV ECU MIT and MIVG terminals and converter & inverter M–INVT, M–GINV terminals (See page IN–41). HINT: Confirm that there is no open circuit in the wire harness. If the voltage between the HV ECU MIT or MIVG terminal and body ground is always more than 5V with the ignition ON, the motor inverter temperature sensor circuit has +B short. NG Repair or replace wire harness. OK Check for open in motor inverter temperature sensor and then replace converter & inverter assembly. Check motor inverter temperature sensor (See page HV–14). 2001 PRIUS (RM778U) DI–275 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU checks the line connection of the motor inverter stop signal circuit and enters the fail safe mode (limited output driving) if malfunction is detected. DTC P3125 – Information code 278, 280 INF. Code. Detecting Condition Trouble Area 278 +B short in motor inverter stop signal circuit 280 Open or GND short in motor inverter stop signal circuit
Converter & inverter assembly
Wire harness WIRING DIAGRAM Hybrid Vehicle Control ECU Inverter 7 G M–SINV I10 M–GINV 6 I9 B 21 H11 MSIV 26 H11 MIVG A14121 INSPECTION PROCEDURE 1 Check for open, short and +B short in wire harness between HV ECU MSIV and MIVG terminals and converter & inverter assembly M–SINV and M–GIVN terminals (See page IN–41). HINT: The motor inverter stop signal circuit has +B short if the voltage between the HV ECU MSIV or MIGV terminal and body ground is always more than 13 V with the ignition ON (”READY” light OFF). NG OK Replace converter & inverter assembly. 2001 PRIUS (RM778U) Repair or replace wire harness. DI–276 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION DTC P3125 – Information code 279, 281, 282 INF. Code. Detecting Condition 279 Over voltage of inverter 281 Voltage drop of inverter power source 282 Inverter circuit broken Trouble Area
Converter & inverter assembly INSPECTION PROCEDURE If the information code 279 or 281 is output, check if other DTC or information codes are recorded. If they are recorded, check and repair those codes first. If the information code 279 or 281 alone is recorded, replace the converter & inverter assembly. If the information code 282 is output, replace the converter & inverter assembly. 2001 PRIUS (RM778U) DI–277 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU checks the line connection of the motor inverter fail signal circuit and detects malfunction. DTC P3125 – Information code 283, 285 INF. Code. Detecting Condition Trouble Area 283 +B short in motor inverter fail signal circuit 285 Open or GND short in motor inverter fail signal circuit
Converter & inverter assembly
Wire harness WIRING DIAGRAM Hybrid Vehicle Control ECU Inverter 6 I9 B 8 M–FINV I10 B M–GINV 26 H11 MIVG 14 H11 MFIV A14121 INSPECTION PROCEDURE 1 Check for open, short and +B short in wire harness between HV ECU MFIV and MIVG terminals and converter & inverter assembly M–FINV and M–GINV terminals (See page IN–41). HINT: The motor inverter fail signal circuit has +B short if the voltage between the HV ECU MIVG or MFIV terminal and body ground is always more than 13 V with the ignition ON (”READY” light OFF). NG OK Replace converter & inverter assembly. 2001 PRIUS (RM778U) Repair or replace wire harness. DI–278 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION DTC P3125 – Information code 284, 286, 287 INF. Code. Detecting Condition 284 Inverter overheating 286 Inverter circuit broken 287 Inverter internal short Trouble Area
Converter & inverter assembly INSPECTION PROCEDURE If the information code 284 or 287 is output, check if other DTC or information codes are recorded. If they are recorded, check and repair those codes first. If the information code 284 or 287 alone is recorded, replace the converter & inverter assembly. If the information code 286 is output, replace the converter & inverter assembly. 2001 PRIUS (RM778U) DI–279 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU detects the malfunction of the motor inverter current sensor. It detects the malfunction of the sensor system, not of the high voltage system. DTC P3125 – Information code 288, 289, 290, 292, 294, 296, 297, 298, 300, 302, INF. Code. Detecting Condition Trouble Area 289 Open in motor inverter current sensor (V phase sub sensor) 292 Open in motor inverter current sensor (V phase main sensor) 297 Open in motor inverter current sensor (W phase sub sensor) 300 Open in motor inverter current sensor (W phase main sensor) 288 Motor inverter current sensor malfunction (V phase sub sensor) 290 Motor inverter current sensor malfunction (V phase main sensor) 294 Motor inverter current sensor V phase performance problem 296 Motor inverter current sensor malfunction (W phase sub sensor) 298 Motor inverter current sensor malfunction (W phase main sensor) 302 Motor inverter current sensor W phase performance problem
Converter C t & iinverter t assembly bl
Wire harness WIRING DIAGRAM Hybrid Vehicle Control ECU Inverter M–GINV M–IVA M–IVB M–IWB M–IWA 6 I9 1 I10 3 I10 4 I10 2 I10 B B W G R 26 H11 MIVG 16 H11 MIVA 7 H11 MIVB 17 H11 MIWB 25 H11 MIWA A14123 2001 PRIUS (RM778U) DI–280 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check continuity of wire harness between HV ECU and converter & inverter assembly (See page IN–41). OK: Continuity: Less then 1 Ω HV ECU Terminals Inverter Terminals MIVA M–IVA MIVB M–IVB MIWA M–IWA MIWB M–IWB MIVG M–GINV NG OK Replace converter & inverter assembly. 2001 PRIUS (RM778U) Repair or replace wire harness. DI–281 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU detects the malfunction of the motor inverter current sensor. It detects the malfunction of the sensor system, not of the high voltage system. DTC P3125 – Information code 291, 293, 295, 299, 301, 303 INF. Code. Detecting Condition Trouble Area 291 293 295 When there is a history that the state of malfunction contin continued during g inverter fail safe mode. 299
Converter & inverter assembly
Wire harness 301 303 WIRING DIAGRAM Hybrid Vehicle Control ECU Inverter M–GINV M–IVA M–IVB M–IWB M–IWA 6 I9 1 I10 3 I10 4 I10 2 I10 B B W G R 26 H11 MIVG 16 H11 MIVA 7 H11 MIVB 17 H11 MIWB 25 H11 MIWA A14123 2001 PRIUS (RM778U) DI–282 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check continuity of wire harness between HV ECU and converter & inverter assembly (See page IN–41). OK: Continuity: Less then 1 Ω HV ECU Terminals Inverter Terminals MIVA M–IVA MIVB M–IVB MIWA M–IWA MIWB M–IWB MIVG M–GINV NG Repair or replace wire harness. OK 2 Is there DTC P3100 being output? YES NO Replace converter & inverter assembly. 2001 PRIUS (RM778U) Check applicable DTC. DI–283 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU detects the malfunction of the motor inverter current sensor. It detects the malfunction of the sensor system, not of the high voltage system. DTC P3125 – Information code 306, 307 INF. Code. Detecting Condition 306 Failure in monitoring motor torque performance 307 Abnormal current value of motor Trouble Area
Converter C t & iinverter t assembly bl INSPECTION PROCEDURE If the information code 306 or 307 is output, check if other DTC or information codes are recorded. If they are recorded, check and repair those codes first. If the information code 306 or 307 alone is recorded, replace the converter & inverter assembly. CIRCUIT DESCRIPTION If the HV ECU detects the collision signal from the airbag or inverter, the HV ECU recognizes it as the destruction of the vehicle and then shuts down the high voltage system to ensure safety. DTC P3125 – Information code 308 INF. Code. 308 Detecting Condition Input of collision signal from airbag or inverter Trouble Area – HINT: When the vehicle collision occurs and the airbag is deployed, this information code will be recorded and the high voltage system will be shut down. 2001 PRIUS (RM778U) DI–284 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU checks the line connection of the motor gate shutdown signal circuit and detects malfunction. DTC P3125 – Information code 304, 305 INF. Code. Detecting Condition Trouble Area 304 +B short in motor gate shutdown signal circuit 305 Open or GND short in motor gate shutdown signal circuit
Converter & inverter assembly
Wire harness WIRING DIAGRAM Hybrid Vehicle Control ECU Inverter 4 M–SDOWN I9 Y 13 H11 MSDN A14120 2001 PRIUS (RM778U) DI–285 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check for open, short and +B short in wire harness between HV ECU MSDN terminal and converter & inverter assembly M–SDOWN terminals (See page IN–41). HINT: Confirm that there is no open circuit in the wire harness. The motor gate shutdown signal circuit has +B short if the battery voltage is always applied to the HV ECU MSDN terminal with the ignition ON. NG OK Replace converter & inverter assembly. 2001 PRIUS (RM778U) Repair or replace wire harness. DI–286 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU detects faulty line connection inside the inverter. DTC P3125 – Information code 309 INF. Code. 309 Detecting Condition Trouble Area Open or short in generator inverter switching wiring (GUU, GVU, GWU)
Wire harness
Converter & inverter assembly WIRING DIAGRAM Hybrid Vehicle Control ECU Inverter 3 G–WU I11 2 G–VU I11 1 G–UU I11 G W R 3 H11 GWU 2 H11 GVU 1 H11 GUU A14124 2001 PRIUS (RM778U) DI–287 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check for open and short in wire harness between HV ECU terminals (GUU, GVU, GWU) and inverter terminals. NG Repair or replace wire harness. OK 2 Is there DTC P3100 being output? YES NO Replace converter & inverter assembly. 2001 PRIUS (RM778U) Check applicable DTC. DI–288 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU detects faulty line connection inside the inverter. DTC P3125 – Information code 311 INF. Code. 311 Detecting Condition Trouble Area
Converter & inverter assembly
Wire harness Generator inverter malfunction WIRING DIAGRAM Hybrid Vehicle Control ECU Inverter 4 G–SDOWN I11 Y 12 H11 GSDN A14120 INSPECTION PROCEDURE 1 Check for open and short in wire harness between HV ECU GSDN terminal and converter & inverter S–DOWN terminal. NG OK Replace converter & inverter assembly. 2001 PRIUS (RM778U) Repair or replace wire harness. DI–289 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU checks the generator temperature and controls the load limitation in order to prevent the generator from overheating. Also, it detects the abnormality of the line connection of the generator temperature sensor and the malfunction of the sensor itself. DTC P3125 – Information code 312, 313, 314, 315 INF. Code. Detecting Condition Trouble Area 312 Open or +B short in generator inverter temperature sensor 313 GND short in generator inverter temperature sensor 314 Generator inverter temperature sensor malfunction 315 Generator inverter temperature sensor performance problem
Converter C t & iinverter t assembly bl
Wire harness WIRING DIAGRAM Hybrid Vehicle Control ECU Inverter M–INVT 5 I11 6 M–GINV I11 L B 23 H11 GIT 27 H11 GIVG A14121 2001 PRIUS (RM778U) DI–290 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check for open, short and +B short in wire harness between HV ECU GIT and GIVG terminals and converter & inverter G–GINV or G–GINV terminals (See page IN–41). HINT: Confirm that there is no open circuit in the wire harness. The generator inverter temperature sensor circuit has +B short if the voltage between the HV ECU GIT or GIVG terminal and body ground is always more than 5V with the ignition ON. NG Repair or replace wire harness. OK Check for open in generator inverter temperature sensor and then replace converter & inverter assembly. Check generator inverter temperature sensor (See page HV–14). 2001 PRIUS (RM778U) DI–291 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU checks the line connection of the generator inverter stop signal circuit and enters the fail safe mode (limited driving) if malfunction is detected. DTC P3125 – Information code 316, 318 INF. Code. Detecting Condition Trouble Area 316 +B short in generator inverter stop signal circuit 318 Open or GND short in generator inverter stop signal circuit
Converter & inverter assembly
Wire harness WIRING DIAGRAM Hybrid Vehicle Control ECU Inverter 6 G–GINV I11 B 7 G–SINV I12 G 27 H11 GIVG 15 H11 GSIV A14121 2001 PRIUS (RM778U) DI–292 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check for open, short and +B short in wire harness between HV ECU GSIV and GIVG terminals and converter & inverter assembly G–SINV and G–GINV terminals (See page IN–41). HINT: The generator inverter stop signal circuit has +B short if the voltage between the HV ECU GSIV or GIVG terminal and body ground is always more than 13 V with the ignition ON (”READY” light OFF). NG Repair or replace wire harness. OK Replace converter & inverter assembly. CIRCUIT DESCRIPTION DTC P3125 – Information code 317, 319, 320 INF. Code. Detecting Condition 317 Over voltage of inverter 319 Voltage drop of inverter power source 320 Inverter circuit broken Trouble Area
Converter & inverter assembly INSPECTION PROCEDURE If the information code 317 or 319 is output, check if other information codes are recorded. If they are recorded, check and repair those codes first. If the information code 317 or 319 alone is recorded, replace the converter & inverter assembly. If the information code 320 is output, replace the converter & inverter assembly. 2001 PRIUS (RM778U) DI–293 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU checks the line connection of the generator inverter fail signal circuit and detects malfunction. DTC P3125 – Information code 321, 323 INF. Code. Detecting Condition Trouble Area 321 +B short in generator inverter fail signal circuit 323 Open or GND short in generator inverter fail signal circuit
Converter & inverter assembly
Wire harness WIRING DIAGRAM Hybrid Vehicle Control ECU Inverter 6 G–GINV I11 B 27 H11 GIVG 8 G–FINV I12 B 24 H11 GFIV A14121 2001 PRIUS (RM778U) DI–294 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check for open, short and +B short in wire harness between HV ECU GFIV and GIVG terminals and converter & inverter assembly G–FINV and G–GINV terminals (See page IN–41). HINT: The generator inverter fail signal circuit has +B short if the voltage between the HV ECU GFIV or GIVG terminal and body ground is always more than 13 V with the ignition ON (”READY” light OFF). NG Repair or replace wire harness. OK Replace converter & inverter assembly. CIRCUIT DESCRIPTION DTC P3125 – Information code 322, 324, 325 INF. Code. Detecting Condition 322 Inverter overheating 324 Inverter circuit broken 325 Inverter internal short Trouble Area
Converter & inverter assembly INSPECTION PROCEDURE If the information code 322 or 325 is output, check if other information codes are recorded. If they are recorded, check and repair those codes first. If the information code 322 or 325 alone is recorded, replace the converter & inverter assembly. If the information code 324 is output, replace the converter & inverter assembly. 2001 PRIUS (RM778U) DI–295 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU detects the malfunction of the generator inverter current sensor. It detects the malfunction of the sensor system, not of the high voltage system. DTC P3125 – Information code 326, 327, 328, 330, 332, 334, 335, 336, 338, 340 INF. Code. Detecting Condition Trouble Area 327 Open in generator inverter current sensor (V phase sub sensor) 330 Open in generator inverter current sensor (V phase main sensor) 335 Open in generator inverter current sensor (W phase sub sensor) 338 Open in generator inverter current sensor (W phase main sensor) 326 Generator inverter current sensor malfunction (V phase sub sensor) 328 Generator inverter current sensor malfunction (V phase main sensor) 332 Generator inverter current sensor V phase performance problem 334 Generator inverter current sensor malfunction (W phase sub sensor) 336 Generator inverter current sensor malfunction (W phase main sensor) 340 Generator inverter current sensor W phase performance problem
Converter & inverter assembly
Wire harness WIRING DIAGRAM Hybrid Vehicle Control ECU Inverter 19 G–IVA 1 I12 B G–IVB 3 I12 W G–IWB 4 I12 G G–IWA 2 I12 R 28 H11 GIWA 5 G–INVT I11 L 23 H11 GIT H11 GIVA 8 H11 GIVB 18 H11 GIWB A14123 2001 PRIUS (RM778U) DI–296 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check continuity of wire harness between HV ECU and converter & inverter assembly (See page IN–41). OK: Continuity: Less then 1 Ω HV ECU Terminals Inverter Terminals GIVA G–IVA GIVB G–IVB GIWA G–IWA GIWB G–IWB GIVG G–GINV NG OK Replace converter & inverter assembly. 2001 PRIUS (RM778U) Repair or replace wire harness. DI–297 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU detects the malfunction of the generator inverter current sensor. It detects the malfunction of the sensor system, not of the high voltage system. DTC P3125 – Information code 329, 331, 333, 337, 339, 341 INF. Code. Detecting Condition Trouble Area 329 331 333 When there is a history that the state of malfunction contin continued during g inverter fail safe mode 337
Converter & inverter assembly
Wire harness 339 341 WIRING DIAGRAM Hybrid Vehicle Control ECU Inverter 19 G–IVA 1 I12 B G–IVB 3 I12 W G–IWB 4 I12 G G–IWA 2 I12 R 28 H11 GIWA 5 G–INVT I11 L 23 H11 GIT H11 GIVA 8 H11 GIVB 18 H11 GIWB A14123 2001 PRIUS (RM778U) DI–298 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check continuity of wire harness between HV ECU and converter & inverter assembly (See page IN–41). OK: Continuity: Less then 1 Ω HV ECU Terminals Inverter Terminals GIVA G–IVA GIVB G–IVB GIWA G–IWA GIWB G–IWB GIVG G–GINV NG Repair or replace wire harness. OK 2 Is there DTC P3100 being output? YES NO Replace converter & inverter assembly. 2001 PRIUS (RM778U) Check applicable DTC. DI–299 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU detects the malfunction of the generator inverter current sensor. It detects the malfunction of the sensor system, not of the high voltage system. DTC P3125 – Information code 344, 345 INF. Code. Detecting Condition 344 Failure in monitoring generator torque performance 345 Abnormal current value of generator Trouble Area
Converter C t & iinverter t assembly bl INSPECTION PROCEDURE If the information code 344 or 345 is output, check if other DTC or information codes are recorded. If they are recorded, check and repair those codes first. If the information code 344 or 345 alone is recorded, replace the converter & inverter assembly. 2001 PRIUS (RM778U) DI–300 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU checks the line connection of the generator gate shutdown signal circuit and detects malfunction. DTC P3125 – Information code 342, 343 INF. Code. Detecting Condition Trouble Area 342 +B short in generator gate shutdown signal circuit 343 Open or GND short in generator gate shutdown signal circuit
Converter C t & iinverter t assembly bl
Wire harness WIRING DIAGRAM Hybrid Vehicle Control ECU Inverter 4 G–SDOWN I11 Y 12 H11 GSDN A14120 2001 PRIUS (RM778U) DI–301 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check for open, short and +B short in wire harness between HV ECU GSDN terminal and converter & inverter assembly G–SDOWN terminals (See page IN–41). HINT: Confirm that there is no open circuit in the wire harness. The generator gate shutdown signal circuit has +B short if the battery voltage is always applied to the HV ECU GSDN terminal with the ignition ON. NG OK Replace converter & inverter assembly. 2001 PRIUS (RM778U) Repair or replace wire harness. DI–302 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM DI839–02 DTC P3130 Inverter Cooling System Malfunction CIRCUIT DESCRIPTION The HV ECU checks the operation of the inverter water pump and detects malfunction. HINT:
When using an OBD scan tool other than TOYOTA hand–held tester, check all the steps.
When using TOYOTA hand–held tester, confirm the information code and check it. DTC P3130 – Information code 346 INF. code. 346 Detecting Condition Trouble Area
Inverter water pump
IG2 relay
Wire harness Water pump system malfunction WIRING DIAGRAM Engine Room J/B Instrument Panel J/B 2 2C W–R 5 2B I15 Ignition SW AM2 7 1 2G 11 2G W–R B–W IG2 Relay 9 1J 5 3 1J 1 2 1B B–W 2 1A B–W 14 IK1 B–W 2 W3 3 3 1K W–B W–B W–B 1 2 Water Pump Motor W–B AM2 A J7 J/C IG2 6 B Fusible Link Block No. 1 1 1 F12 F13 Fusible Link Block No. 2 1 MAIN F18 A B–G A W–B J1 J/C IE Battery A14736 2001 PRIUS (RM778U) DI–303 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check wire harness (See page IN–41). HINT: After removing the IG2 relay, check the electrical condition of each terminal.
No. 1 terminal: With the IG switch ON, 10 – 14 V
No. 2 terminal : Continuity between the IG2 relay No. 2 terminal and body ground (less than 1 Ω )
No. 3 terminal: Continuity between the IG2 relay No. 3 terminal and water pump No. 2 terminal (less than 1 Ω )
No. 5 terminal: Always 10 – 14 V Continuity between the water pump No. 1 terminal and body ground (less than 1 Ω ) NG OK 2001 PRIUS (RM778U) Repair or replace wire harness. DI–304 DIAGNOSTICS 2 – HYBRID VEHICLE CONTROL SYSTEM Check IG2 relay. Continuity 2 Ohmmeter Ohmmeter 1 5 3 No Continuity 2 Ohmmeter 1 5 Battery PREPARATION: Remove the IG2 relay from the engine room J/B. CHECK: (a) Using an ohmmeter, check that there is continuity between terminals 1 and 2. (b) Check that there is no continuity between terminals 3 and 5. (c) Apply battery voltage across terminals 1 and 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. OK: (a) Continuity (b) No continuity (c) Continuity 3 Continuity S04947 S04946 NG Replace IG2 relay. A14712 OK Confirm that water pump is defective and then replace it. Check water pump (See page HV–26). CIRCUIT DESCRIPTION DTC P3130 – Information code 347 INF. code. 347 Detecting Condition Electric cooling fan system malfunction Trouble Area
Electric cooling fan system INSPECTION PROCEDURE If this information code is output, check the electric cooling fan system (See page CO–20). 2001 PRIUS (RM778U) DI–305 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM DI83A–02 DTC P3135 Circuit Breaker Sensor Malfunction CIRCUIT DESCRIPTION The HV ECU checks the line connection of the circuit breaker sensor (collision signal) and gives warning to the driver if malfunction is detected. DTC P3135 – Information code 348, 349 INF. code. Detecting Condition 348 GND short in circuit breaker sensor 349 Open or +B short in circuit breaker sensor Trouble Area
Circuit breaker sensor
Wire harness WIRING DIAGRAM Hybrid Vehicle Control ECU BR–B 14 H12 AS1G 1 C3 Circuit Breaker Sensor 2 G–R 15 H12 AS1 A14136 2001 PRIUS (RM778U) DI–306 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check for open, short and +B short in wire harness between circuit breaker sensor No. 1 and No. 2 terminals and HV ECU AS1G and AS1 terminals (See page IN–41). HINT: Confirm that there is no open circuit in the wire harness. The circuit breaker sensor circuit has +B short if the voltage of the HV ECU AS1 terminal is more than 5V with the ignition ON. NG Repair or replace wire harness. OK Check for open in resistance between circuit breaker sensor terminals and then replace circuit breaker sensor (Circuit breaker sensor resistance: 820 ± 82 Ω). 2001 PRIUS (RM778U) DI–307 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM DI83B–02 DTC P3140 Interlock Malfunction CIRCUIT DESCRIPTION If the HV ECU detects the operation of the safety devices (removal of the service plug, inverter terminal cover and sensor cover) while the vehicle is not running (with the vehicle is stopped), it will shut down the system main relay. It the safety devices are correctly installed, it will resume the normal operation after the power source is supplied again. If it does not, there is a possibility of an open circuit, so perform the same inspection as the information code 351. HINT:
When using an OBD scan tool other than TOYOTA hand–held tester, check all the steps.
When using TOYOTA hand–held tester, confirm the information code and check it. DTC P3140 – Information code 350 INF. code. 350 Detecting Condition Safety devices operating with vehicle is stopped (ILK signal ON) 2001 PRIUS (RM778U) Trouble Area – DI–308 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM CIRCUIT DESCRIPTION The HV ECU records the information code 351 and gives warning to the driver when it detects an open circuit in the interlock signal circuit while the vehicle is running. In this case, it does not shut down the high voltage system. DTC P3140 – Information code 351 INF. code. 351 Detecting Condition Trouble Area Open circuit in interlock signal circuit while vehicle is running
Interlock switch
Inverter terminal cover
Converter & inverter assembly
Wire harness WIRING DIAGRAM 6 CVRSW I10 V–R 4 IH1 Hybrid Vehicle Control ECU I17 Interlock SW Inverter V–R 0 2 1 10 IF1 0 4 H13 ILK A14141 2001 PRIUS (RM778U) DI–309 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check installation condition of inverter terminal cover and sensor cover. NG Install them correctly. OK 2 Check continuity of wire harness between interlock switch No. 1 terminal and HV ECU ILK terminal and interlock switch No. 2 terminal and inverter CVRSW terminal (See page IN–41). OK: Continuity: Less than 1 Ω NG Repair or replace wire harness. OK 3 Check continuity between inverter CVRSW terminal and body ground (See page IN–41). OK: Continuity: Less than 1 Ω NG Replace converter & inverter assembly. OK Confirm that interlock switch is defective and replace it. Check interlock switch (See page HV–38) 2001 PRIUS (RM778U) DI–310 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM DI83C–02 DTC P3145 Vehicle Speed Sensor Circuit Malfunction CIRCUIT DESCRIPTION DTC P3145 – Information code 352 INF. code. 352 Detecting Condition Trouble Area No input of vehicle speed signal during cruise control driving
Wire harness WIRING DIAGRAM C10 Combination Meter Hybrid Vehicle Control ECU Instrument Panel J/B L 13 6 7 2A 2B V–W G J27 J/C G J28 V–W 19 IE1 V–W 8 H12 SPDI A14138 2001 PRIUS (RM778U) DI–311 DIAGNOSTICS – HYBRID VEHICLE CONTROL SYSTEM INSPECTION PROCEDURE 1 Is DTC P0500 of engine ECU being output? YES Check DTC P0500. NO Check continuity of wire harness between J26 J/B G terminal and HV ECU SPDI terminal and repair wire harness. 2001 PRIUS (RM778U) DI–313 DIAGNOSTICS – HV BATTERY CONTROL SYSTEM DI2VS–03 CUSTOMER PROBLEM ANALYSIS CHECK Prius Problem Check Sheet Person in Charge at Headquarters Name of Dealer Person in Charge at Dealer Office Please fill in the blanks within bold frame. Vehicle Specifications Model Code NHW11– Problem Occurrence Date . . . Frame No. Service Entry Date . . Unit No. etc. Vehicle Delivery Date . . Option ( ( ) Navigation ) others( (equipped by ( ) ) MOP ( Registration date ) dealer) Contents of complaint (Status when and before/after occurring in the order of events as correct as possible) km miles Odometer Reading : ( ) Cold climate . . specification Characteristics of Customer ( ) Male Gender ( ) Female Age Occupation Vehicle used before Main use area city area ( )% suburbs ( )% mountain area Interview Results Others ( Frequency in use ( ) ( )% )% times/day or week or month Others Driving Condition Vehicle Speed km/h mph ( ) when starting Road Condition ( ) flat road ( ) when starting ( ) right after starting ( ) until min. after starting ( ) until min. after starting of driving HV Battery indication ( ) up hill ( ) down ( ) 4/4 ( ) 3/4 hill incline of ( ) 2/4 ( ) 1/4 ° /% ( ) unidentified ( ) when according distance km ( ) When Shift position mph normal driving (indication) ( ) dry paved road ( ) when ( )P ( )R ( )N ( ) when shopping ( ) D ( ) B decelerating ( ) wet paved road system ( ) when operating ( ) when braking ( ) rough paved road → ( ) when shopping ( ) unpaved road Status of engine ( ) no indication ( ) when parking ( ) snowy/frozen ( ) while shopping ( ) unidentified road ( ) when turning engine ( ) bump/curb ( ) when starting A/C status ( ) when engine ( ) A/C ( ) FULL ABS actuating ( ) others ( ) when revolving ( ) OFF ( ) others ( ) ( ) unidentified ( ) engine 2001 PRIUS (RM778U) Others Vehicle Condition Warning light (MIL) ( ) ON ( ) OFF ( ) PS ( ) main battery ( ) HV! ( ) engine ( ) charge ( ) output control ( ) brake ( ) ABS ( ) others ( Weather: Temperature: °C °F Brake operation ( ) brake slowly ( ) Brake suddenly ( ) use two pedals system Frequency in occurrence ( ) always ( ) sometimes ( ) only once ) Fuel level ( ) segments DI–314 DIAGNOSTICS Verification Results of Warning Light ( ) ON ( ) OFF Verification Results of Diagnostic Code ( ) HV HV ( ) HV battery INF. code ( ) output control warning light Vehicle Verification Results HV BATTERY CONTROL SYSTEM Engine ( ) engine ( ) charge ( ) PS ( ) brake ( ) ABS ( ) others ( – HV battery Brake PS ) Vehicle Inspection Results (Verification items, reason to identify/presume the cause parts, etc.) Duplication Status ( ) always ( ) sometimes ( ) no reproduction Confirmation Results After Repair Replacement Parts ( ( ( problem parts: 2001 PRIUS (RM778U) No/Yes (Sending date: . . ) ) Normal ) reproduction ) others ( ) DI–315 DIAGNOSTICS – HV BATTERY CONTROL SYSTEM DI820–01 PRE–CHECK 1. (a) (b) B04757 (c) (d) 2. (a) A14089 2001 PRIUS (RM778U) A14090 PRECAUTION To distinguish a trouble and replace a defective part, take necessary preventive measures against an electric shock (See page IN–4). Some portions of the wiring harness in the THS vehicle have the circuits, to which a high voltage is applied. To prevent an electrical shock, be sure to observe the following: (1) Wear insulated gloves during inspection. (2) Remove a service plug and do not start any repair operation before 5 minutes have passed, then confirm that the voltage at the output terminals has dropped down to 12 V or less. (3) Use insulated tools during inspection. (4) When disengaging wiring connectors, hold the connector bodies to avoid pulling the wires. When engaging wiring connectors, be sure to engage them securely. Do not leave tools or parts (bolts, nuts, etc.) inside the cabin. Do not carry metallic objects such as mechanical pencils or scales. DIAGNOSIS SYSTEM Description
The HV Battery ECU has a self–diagnosis system by which malfunction in the computer itself or in Hybrid System is detected and the master warning light in the combination meter and the Hybrid system warning light in the multi–information display lights up. DI–316 DIAGNOSTICS –
TOYOTA hand–held tester
DLC3 F12396 (b) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 HV BATTERY CONTROL SYSTEM To check the Diagnostic Trouble Codes (DTC), connect the TOYOTA hand–held tester to the Data Link Connector 3 (DLC3) on the vehicle. The TOYOTA hand–held tester also enables you to erase the DTC and check freeze frame data and various forms of THS data. Freeze frame data: Freeze frame data records the battery condition when a malfunction is detected. When troubleshooting, this is useful for knowing the battery condition. Check the DLC3. The HV control ECU conforms to ISO 14230 for communication. The terminal arrangement of the DLC3 complies with SAEJ1962 and matches the ISO 14230 format. DLC3 A04550 Terminal No. Connection/Voltage or Resistance Condition 7 Bus
Line/Pulse generation During transmission 4 Chassis Ground ↔ Body Ground/1 Ω or less Always 5 Signal Ground ↔ Body Ground/1 Ω or less Always 16 Battery Positive ↔ Body Ground/10 – 15 V Always HINT: If your display shows UNABLE TO CONNECT TO VEHICLE when you have connected the cable of the TOYOTA hand–held tester to the DLC3, turned the motor switch ON and operated the tester, there is a problem in the vehicle or tool.
If communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle.
If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department. 3. INSPECT DIAGNOSIS (a) Check the auxiliary battery. (1) Measure the voltage of the auxiliary battery. Voltage: 10 – 15 V 2001 PRIUS (RM778U) DI–317 DIAGNOSTICS – HV BATTERY CONTROL SYSTEM (2) (b) Inspect the auxiliary battery, fuses, fusible links, wiring harness, connectors and ground. Check the master warning light. (1) Turn the ignition switch ON and confirm that the master warning light comes on. HINT: If the master warning light does not come on, suspect a burnt fuse, burnt bulb, or open in wiring harness. A14089 (2) When the ”READY” light is ON, the master warning light should go off. If the lamp remains on, the diagnosis system has detected a malfunction or abnormality in the system. B12009 TOYOTA hand–held tester DLC3 F12396 2001 PRIUS (RM778U) (c) Check the DTC. (1) Prepare a TOYOTA hand–held tester. (2) Connect the TOYOTA hand–held tester to the DLC3. (3) Turn the ignition switch ON and push the TOYOTA hand–held tester main switch ON. (4) Use the TOYOTA hand–held tester to check the DTC and freeze frame data and note them down. (For operating instructions, see the TOYOTA hand– held tester operator’s manual). Since the HV battery ECU stores DTC and freeze frame data, when troubleshooting, check all of the DTC, write down the freeze fame data and perform inspection according to the procedures of ”Circuit Inspection”. Because the HV battery ECU is communicating with the HV ECU, if any DTC is stored in the HV battery ECU, check and record DTC stored in the HV ECU (For tables for DTC, see page DI–177). (5) See a related page to confirm details of the DTC. DI–318 DIAGNOSTICS TOYOTA hand–held tester (d) – HV BATTERY CONTROL SYSTEM Clear DTC after completion of repair. (1) Connect the TOYOTA hand–held tester to the DLC3. HINT: Before clearing, check that DTC for the HV battery ECU, DTC for the ECU which is related with freeze frame data and the freeze frame data are recorded. DLC3 (2) Operate the TOYOTA hand–held tester to erase the DTC (See the TOYOTA hand–held tester operaF12396 tor’s manual.). CHECK FOR INTERMITTENT PROBLEMS Perform a simulation test (See page IN–30). 4. (a) HINT: In the simulation test, reproduce the condition at trouble occurrence based on the customer’s comments and the freeze frame data recorded with the DTC. (b) Check the connector and terminal (See page IN–41). (c) Handle the connector (See page IN–41). 5. TOYOTA HAND–HELD TESTER DISPLAY ITEMS TOYOTA hand–held tester display Measurement Item BATTERY SOC Battery State of charge ONB CHARGE TIME Cumulative number of times of on–board equalizing charging BATTERY LO TIME Cumulative number of times of battery dies DC INHIBIT TIME Cumulative number of times of discharge inhibition IB MAIN BATTERY IB main battery current (with correction) BATT BLOCK V# Battery block voltage BAT BLOCK MIN V Battery block minimum voltage MIN BAT BLOCK # Minimum voltage battery block BAT BLOCK MAX V Battery block maximum voltage MAX BAT BLOCK # Maximum voltage battery block BATT INSIDE AIR Ambient temperature inside battery pack BATTERY TOO HI # Cumulative number of times of too–high battery voltage VMF FAN VOLTAGE Battery cooling fan voltage AUX. BATT V Auxiliary battery voltage WIN Charge restriction value WOUT Discharge restriction value DELTA SOC Difference between MAX. and MIN. values of SOC at every battery block. SBLW FAN ST RQS SBL cooling fan stop request signal COOLING FAN HI Cooling fan operation in high speed COOLING FAN MID Cooling fan operation in middle speed COOLING FAN LO Cooling fan operation in low CCTL Off–board equalizing charge control signal EQC0 DF RELAY EQC0 dead front relay EQTR CHARGE ST EQTR uniform charging start signal ONBORD CHARGE On–board equalizing charging status PRE ONBORDE CH Pre–On–board charging status NORMAL STATUS Normal status INSIDE RESIST # Inside resistance 2001 PRIUS (RM778U) DI–319 DIAGNOSTICS – HV BATTERY CONTROL SYSTEM BATT TEMP # Battery temperature ECU CODE ECU code IG OFF HOUR Average time of IG OFF IG ON HOUR Average time of IG ON ET OFF CHG HR Estimation of time to finish OFF BOARD DTC The number of stored DTC 2001 PRIUS (RM778U) DI–323 DIAGNOSTICS – HV BATTERY CONTROL SYSTEM DI824–01 CIRCUIT INSPECTION DTC P1600 Back Up Power Source Circuit Malfunction CIRCUIT DESCRIPTION Battery positive voltage is supplied to terminal AM of the Battery ECU even when the ignition switch is OFF to read the DTC memory and freeze frame data adaptive control value memory, etc. DTC No. P1600 DTC Detecting Condition Trouble Area
Open in back up power source circuit
Battery ECU Open in back up power source circuit HINT: If DTC P1600 appears, the Battery ECU does not store any other DTC. WIRING DIAGRAM Battery ECU Engine Room J/B HV 1 1B 11 1F J2 J/C G–Y B G–Y B 5 IH1 G–Y 1 B17 AM B Fusible Link Block No. 1 1 1 F12 F13 B–G Fusible Link Block No. 2 MAIN 1 F18 Battery 2001 PRIUS (RM778U) A14078 DI–324 DIAGNOSTICS – HV BATTERY CONTROL SYSTEM INSPECTION PROCEDURE HINT: Read freeze frame data using a TOYOTA hand–held tester or OBD II scan tool. Because freeze frame data records the battery condition when the malfunction is detected. When troubleshooting, this is useful for knowing the battery condition. 1 Check voltage between terminal AM of Battery ECU connector and body ground. PREPARATION: Remove the luggage trim. CHECK: Measure the voltage between terminal AM of the Battery ECU connector and body ground. OK: Voltage: 9 – 14 V AM A14081 OK Check and replace Battery ECU (See page IN–41). NG 2 Check HV fuse of engine room J/B. PREPARATION: Remove the HV fuse from the engine room J/B. CHECK: Check the continuity of the HV fuse. OK: Continuity Engine Room J/B NG HV Fuse A14082 OK Check and repair harness or connector between battery and HV fuse, and HV fuse and Battery ECU (See page IN–41). 2001 PRIUS (RM778U) Check for short in all harness and components connected to HV fuse. DI–326 DIAGNOSTICS – HV BATTERY CONTROL SYSTEM DI826–01 DTC P3002 HV ECU Communication Malfunction CIRCUIT DESCRIPTION The battery ECU receives information of the AC ECU, system main relay connection signals, etc. sent from the HV ECU, and stores DTC when an error is detected in the receives information. DTC No. P3002 DTC Detecting Condition Trouble Area
Communication bus line
HV ECU No serial signals transmitted from HV ECU HINT: Check DTC of other ECUs and see whether any communication error of the HV ECU is stored or not. If HV communication errors are stored in then one ECU, replace the HV ECU. WIRING DIAGRAM Battery ECU HV ECU 2 HTD+ H13 W 1 IF2 20 HTD– H13 B 2 IF2 W B 6 B17 7 B17 A15624 2001 PRIUS (RM778U) DI–327 DIAGNOSTICS – HV BATTERY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check for open and short in wire harness between HV ECU and battery ECU. PREPARATION: Disconnect the connector from the battery ECU and the HV ECU CHECK: Check that the communication bus line is not short or open. Terminals for checking open and short: HV ECU Terminals Battery ECU Terminals H13 – 2 B17 – 6 H13 – 20 B17 – 7 OK: No open or short. NG Repair or replace the wire harness. OK 2 Stop operation of all optional electric products for vehicle and check if same DTC is stored. NO YES Replace the HV ECU. 2001 PRIUS (RM778U) Stop using product that causes noise. DI–328 DIAGNOSTICS – HV BATTERY CONTROL SYSTEM DI827–01 DTC P3005 High Voltage Fuse Snapped CIRCUIT DESCRIPTION A fuse is set in the service plug to protect high–voltage system parts. DTC No. DTC Detecting Condition P3005 Although interlock switch is connected, voltage of battery block No. 10 is less than specified. Trouble Area
High voltage fuse
Power cable WIRING DIAGRAM Battery ECU Power Cable to System Main Relay, Inverter L–W Service Plug Assembly 6 High Voltage Fuse Battery Block No. 10 Service Plug L to System Main Relay, Inverter 7 Power Cable A13558 2001 PRIUS (RM778U) DI–329 DIAGNOSTICS – HV BATTERY CONTROL SYSTEM INSPECTION PROCEDURE 1 Are there any other codes (besides DTC P3005) and other ECU being output? YES Go to relevant DTC chart. NO 2 Check continuity of high voltage fuse in the service plug assembly and check condition of service plug terminal (Loosened, poor contact, etc.). OK NG Repair or replace the service plug or the high voltage fuse in the service plug assembly. 2001 PRIUS (RM778U) Repair or replace the power cable. DI–332 DIAGNOSTICS – HV BATTERY CONTROL SYSTEM DI82A–01 DTC P3009 Leak Detected CIRCUIT DESCRIPTION Electric leak from the high–voltage system, which may seriously harm the human body, is detected by this code. DTC No. P3009 DTC Detecting Condition Trouble Area
Power cable
HV transaxle
Converter & inverter assembly
Battery cover
System main relay
Battery temperature sensor
Battery ECU
Battery carrier catch bracket
Main battery cable
Service plug assembly
HV battery assembly Electric leak from high–voltage system (Insulating resistance of power cable is 100 kΩ or less.) INSPECTION PROCEDURE 1 Is DTC P3125 of HV ECU being output? YES Go to relevant DTC chart. NO 2 Are there any other codes (Desides DTC P3009) being output? YES NO 2001 PRIUS (RM778U) 4/27/01 Go to relevant DTC chart. DI–333 DIAGNOSTICS 3 – HV BATTERY CONTROL SYSTEM Is DTC P3009 of battery ECU being output? PREPARATION: (a) Before clearing the DTC, check that related DTC and freeze frame data are recorded in the given table. (b) With the shift lever in P, delete this DTC using a TOYOTA hand–held tester. (c) Turn the ignition switch OFF and then ON (Do not turn to ST.), leave it alone for 1 min. and then check for DTC. CHECK: Check that DTC P3009 is detected. YES Go to step 8. NO 4 Is DTC P3009 of battery ECU being output? (Check for battery carrier catch bracket.) PREPARATION: (a) Under step 2 condition, turn the ignition switch OFF and disconnect the negative terminal of the auxiliary battery. (b) Remove the service plug. (c) Using the service plug, turn the interlock counterclockwise to unlock. (d) Remove the 3 nuts and battery carrier catch bracket. (e) Connect the negative terminal of the auxiliary battery and turn the ignition switch ON to clear DTC. HINT: When the ignition switch is turned ON, DTC P3140 is stored in the HV ECU. This happens because the service plug is removed, so continue the operation. (f) After turning the ignition switch OFF, connect the service plug. (g) Turn the ignition switch ON (to ST), leave it alone for 1 min. and then check for DTC. CHECK: Check that DTC P3009 is detected. NO Check for contact between battery carrier catch bracket and power cable and if any defect is identified, replace defective part. HINT: If no defect is identified at inspection, entry of foreign matter or water into the battery assembly or converter & inverter assembly may be possible as a cause. YES 2001 PRIUS (RM778U) DI–334 DIAGNOSTICS 5 – HV BATTERY CONTROL SYSTEM Check insulating resistance of power cable. PREPARATION: (a) Under step 3 condition, turn the ignition switch OFF and disconnect the negative terminal of the auxiliary battery. (b) Remove the service plug. (c) Disconnect the 2 power cables from the converter & inverter. (d) Disconnect the 2 power cables from the HV battery. CHECK: Using a megger (500V), measure the insulating resistance between the power cable and body ground. OK: Insulating resistance: 10MΩ or more NG Replace the power cable. OK 6 Check insulating resistance of power cable of hybrid transaxle. PREPARATION: (a) Under step 4 condition, disconnect the 3 power cables for MG2 and a power cable for MG1 from the converter & inverter assembly. (b) Check that the voltage between each of the 6 terminals of the power cables and body ground is 0 V. CHECK: Using a megger (500V), measure the insulating resistance between each of the 6 terminals and the hybrid transaxle. OK: Insulating resistance: 10MΩ or more NG OK 2001 PRIUS (RM778U) 4/27/01 Replace the hybrid transaxle assembly. DI–335 DIAGNOSTICS 7 – HV BATTERY CONTROL SYSTEM Check insulating resistance of converter & inverter assembly. CHECK: Using a megger (500V), measure the insulating resistance between each of 2 connected parts of the HV battery power cables to the converter & inverter and the converter & inverter itself, and between each of 6 connected parts of MG2/MG1 power cables to the converter & inverter and the converter & inverter itself. and the hybrid transaxle. OK: Insulating resistance: 0.9MΩ NG OK Replace the battery ECU. 2001 PRIUS (RM778U) Replace the converter & inverter assembly. DI–336 DIAGNOSTICS 8 – HV BATTERY CONTROL SYSTEM Is DTC P3009 of battery ECU being output? (Check for battery cover.) PREPARATION: (a) Under step 2 condition, turn the ignition switch OFF and disconnect the negative terminal of the auxiliary battery. (b) Remove the service plug. (c) Using the service plug, turn the interlock counterclockwise to unlock. (d) Remove the 3 nuts and battery carrier catch bracket. (e) Remove the 2 bolts and power cables. (f) Remove the battery cover. (g) Connecting the negative terminal of the auxiliary battery, turn the ignition switch ON and clear the DTC. HINT: When the ignition switch is turned ON, DTC P3140 is stored in the HV ECU. This happens because the service plug is removed, so continue the operation. (h) After turning the ignition switch OFF, connect the service plug. (i) Turn the ignition switch ON (to ST), leave it alone for 1 min. and then check for DTC. CHECK: Check that DTC P3009 is detected. NO Check for contact between battery carrier catch bracket and power cable and if any defect is identified, replace defective part. HINT: If no defect is identified at inspection, entry of foreign matter or water into the battery assembly or converter & inverter assembly may be possible as a cause. YES 2001 PRIUS (RM778U) 4/27/01 DI–337 DIAGNOSTICS 9 – HV BATTERY CONTROL SYSTEM Check insulating resistance of main battery cable. PREPARATION: (a) Under step 7 condition, turn the ignition switch OFF and disconnect the negative terminal of the auxiliary battery. (b) Remove the service plug. (c) Remove the main battery cables. (Disconnect 4 terminals of a long and a short cables connected between the system main relay and the HV battery.) CHECK: Using a megger (500V), measure the insulating resistance between the main battery cable and body ground. OK: Insulating resistance: 10MΩ or more NG Replace the main battery cable. OK 10 Check insulating resistance of system main relay. CHECK: Using a megger (500V), measure the insulating resistance between each of 2 connected parts of the system main relay to the power cables and body ground, and between each of 2 connected parts of the system main relay to the main battery cables and body ground. OK: Insulating resistance: 10MΩ or more NG OK 2001 PRIUS (RM778U) Replace the system main relay. DI–338 DIAGNOSTICS 11 – HV BATTERY CONTROL SYSTEM Check insulating resistance of service plug assembly. PREPARATION: Under step 9 condition, disconnect the cable terminal of the service plug assembly from the HV battery. CHECK: Using a megger (500V), measure the insulating resistance between 2 cable terminals and body ground. OK: Insulating resistance: 10MΩ or more NG Replace the service plug assembly. OK 12 Check insulating resistance of HV battery temperature sensor. PREPARATION: Under step 10 condition, disconnect the HV battery temperature sensor connector from the battery ECU. CHECK: Using a megger (500V), measure the insulating resistance between each terminal of the HV battery temperature sensor and body ground. OK: Insulating resistance: 10MΩ or more NG OK 2001 PRIUS (RM778U) 4/27/01 Replace the HV battery temperature sensor. DI–339 DIAGNOSTICS 13 – HV BATTERY CONTROL SYSTEM Is DTC P3009 of battery ECU being output? PREPARATION: (a) Under step 11 condition, disconnect the HV connector from the battery ECU. (b) Connect the negative terminal of the auxiliary battery (with the service plug removed). (c) Turn the ignition switch ON (not ST) and clear the DTC. HINT: When the ignition switch is turned ON, DTC P3140 is stored in the HV ECU. This happens because the service plug is removed, so continue the operation. CHECK: Check that DTC P3009 is detected. YES Replace the HV battery ECU. NO 14 Check insulating resistance of wire harness for module voltage detection. PREPARATION: (a) Under step 12 condition, turn the ignition switch OFF and disconnect the negative terminal of the auxiliary battery. (b) Remove the 36 nuts and the busbar module on the battery rear side. CHECK: Using a megger (500V), measure the insulating resistance between the connector terminal of the wire harness for the removed module’s voltage detection and body ground. OK: Insulating resistance: 10 MΩ or more NG OK Replace the HV battery ECU. 2001 PRIUS (RM778U) Replace the HV battery assembly. DI–341 DIAGNOSTICS – HV BATTERY CONTROL SYSTEM DI82C–01 DTC P3011–P3029 Battery Block # Malfunction CIRCUIT DESCRIPTION Internal resistance of each battery module is measured, detecting battery deterioration for each block, 1 to 19. Nineteen blocks of battery modules are arranged in the order of 1 to 19 from the ECU side. DTC No. P3011–P3029 DTC Detecting Condition Trouble Area
Battery ECU
Battery pack Battery internal resistance is abnormal. INSPECTION PROCEDURE 1 Are there any other codes (besides DTC P3011–P3029) being outputs? YES Go to relevant DTC chart. NO 2 Check that the block voltage during charging/ discharging. PREPARATION: (a) To ensure safety, conduct this test in a wide, clear level area which provides good traction. (b) Turn ON the ”READY” light. (c) Warm up the engine and turn off the A/C switch. (d) Fully apply the parking brake and chock the 4 wheels. (e) Connect a TOYOTA hand–held tester to DLC3 and select HV BATTERY and then CURRENT DATA. (f) Show voltage of the block corresponding to the DTC and other block (any block except the above– mentioned block). CHECK: (a) Keep your left foot pressed firmly on the brake pedal and shift into the R position. (b) Confirm the engine stopped in the R position. Step on the accelerator pedal until the engine starts, stepping on the brake pedal firmly. (c) Release the accelerator pedal when the engine starts. At the same time, monitor the change of the voltage before engine starting (during discharging) and after engine starting (during charging). 2001 PRIUS (RM778U) 4/27/01 DI–342 DIAGNOSTICS – HV BATTERY CONTROL SYSTEM Voltage Other block voltage B A A: 0.3 V or more B: 0.3 V or more Voltage of the block corresponding to the DTC Discharging (engine stops) Charging (engine starts) Time A16881 OK: Before or after switch–over from discharging to charging, the relationship of the voltage size are reversed and the difference of the voltage is 0.3 V ore more. OK Go to step 5. NG 3 Check that the HV battery blocks voltage swings at stall test. PREPARATION: (a) To ensure safety, conduct this test in a wide, clear level area which provides good traction. (b) Turn ON the ”Ready” light. (c) Warm up the engine and turn off the A/C switch. (d) Fully apply the parking brake and chock the 4 wheels. (e) Connect a TOYOTA hand–held tester to DLC3 and select HV BATTERY and then CURRENT DATA to show ”BAT BLOCK MIN V” and ”BAT BLOCK MAX V” on the TOYOTA hand–held tester. CHECK: (a) Keep your left foot pressed firmly on the brake pedal and shift into the R position. (b) Stepping on the brake pedal, release the accelerator pedal during the engine moving and step on the accelerator pedal during the engine stopping. (c) Continue STEP (b) for more than 20 min. and monitor the swing and the difference of the voltage between the data MAX V and MIN V. 2001 PRIUS (RM778U) DI–343 DIAGNOSTICS – HV BATTERY CONTROL SYSTEM Voltage VMAX data Swing VMIN data Swing Swing Swing The difference of the voltage between the date VMAX and VMIN Test start The engine start Time A16880 OK: Standard voltage swing: Less than 2 V NG Replace the battery ECU (See page IN–41). OK 4 Check the difference of the voltage between the data V MAX and V MIN. Standard voltage difference: Less than 1.2 V YES Replace the battery ECU. (See page IN–41). NO 5 Replace the battery pack assembly, and initialize the battery ECU by performing an active test. 2001 PRIUS (RM778U) 4/27/01 DI–344 DIAGNOSTICS – HV BATTERY CONTROL SYSTEM DI82D–01 DTC P3030 Battery Voltage Detective line Snapped CIRCUIT DESCRIPTION A voltage sensor set in a busbar module circuit measures a voltage of a pair of battery modules and sends signals to the battery ECU. DTC No. P3030 DTC Detecting Condition Trouble Area
Battery ECU
Open in battery voltage detective line
Wire harness, Busbar module Open in battery voltage detective line WIRING DIAGRAM Battery ECU Busbar Module GR – B V–Y GR O LG – B L–O 14 2 15 3 16 4 LG P 17 5 Y–B L–W L LG – R 18 6 7 20 Y P–L 8 21 G L–R 9 22 G–W R 10 23 W L–B 11 24 VBB1 VBB2 VBB3 VBB4 VBB5 VBB6 VBB7 VBB8 VBB9 VBB10 VBB11 VBB12 VBB13 VBB14 VBB15 VBB16 VBB17 VBB18 VBB19 GBB19 A14077 2001 PRIUS (RM778U) 4/27/01 DI–345 DIAGNOSTICS – HV BATTERY CONTROL SYSTEM INSPECTION PROCEDURE 1 Are there any other codes (besides DTC P3030) being outputs? YES Go to relevant DTC chart. NO 2 Check voltage of battery block 1 to 19. CHECK: Connecting a TOYOTA hand–held tester, check the ECU data. HINT: Nineteen blocks of battery modules are arranged in the order of 1 to 19 from the battery ECU side. OK: Standard voltage: 2V or more OK Go to step 4. NG 3 Check that the HV battery blocks voltage swings at stall test. PREPARATION: (a) To ensure safety, conduct this test in a wide, clear level area which provides good traction. (b) Turn ON the ”READY” light. (c) Warm up the engine and turn off the A/C switch. (d) Fully apply the parking brake and chock the 4 wheels. (e) Connect a TOYOTA hand–held tester to DLC3 and select HV BATTERY and then CURRENT DATA to show ”BAT BLOCK MIN V” and ”BAT BLOCK MAX V” on the TOYOTA hand–held tester. CHECK: (a) Keep your left foot pressed firmly on the brake pedal and shift into the R position. (b) Stepping on the brake pedal, release the accelerator pedal during the engine moving and step on the accelerator pedal during the engine stopping. (c) Continue STEP (b) for more than 20 min. and monitor the swing and the difference of the voltage between the data MAX V and MIN V. 2001 PRIUS (RM778U) DI–346 DIAGNOSTICS – HV BATTERY CONTROL SYSTEM Voltage VMAX data Swing VMIN data Swing Swing Swing The difference of the voltage between the date VMAX and VMIN Test start The engine start Time A16880 OK: Standard voltage swing: 2 V or more NG Replace the battery ECU (See page IN–41). OK 4 Check tightening condition of busbar module of block and correct if necessary. OK: The nut is not loosened. Torque: 6 N·m (61 kgf·cm, 4.4 ft·lbf) NG Tighten the nut. OK 5 Check if busbar module connector is properly connected. NG OK 2001 PRIUS (RM778U) 4/27/01 Connect properly, repair or replace. DI–347 DIAGNOSTICS 6 – HV BATTERY CONTROL SYSTEM Continuity check of the busbar module. NG OK Replace the battery ECU (See page IN–41). 2001 PRIUS (RM778U) Replace the busber module (See page IN–41). DI–348 DIAGNOSTICS – HV BATTERY CONTROL SYSTEM DI82E–01 DTC P3060 Battery Temperature sensor Circuit Malfunction CIRCUIT DESCRIPTION A thermistor in the sensor set in a battery pack changes its resistance according to battery bemperature. As the battery temperature falls or rises, the resistance rises or falls accordingly. DTC No. P3060 DTC Detecting Condition Trouble Area
Open or short in battery temperature sensor circuit
Battery temperature sensor circuit range/performance problem
Battery temperature sensor
Connector and wire harness WIRING DIAGRAM Battery ECU Battery Temperature Sensor L 1 L 2 B 3 B 4 W 5 W 6 R 7 R 8 G 9 G 10 TB1 GB1 TB2 GB2 TB3 GB3 TB4 GB4 TB5 GB5 A13557 2001 PRIUS (RM778U) DI–349 DIAGNOSTICS – HV BATTERY CONTROL SYSTEM INSPECTION PROCEDURE 1 Are there any other codes (besides DTC P3060) being output? YES Go to relevant DTC chart. NO 2 Check resistance of battery temperature sensor. PREPARATION: (a) Remove the battery cover (See page HV–5). (b) Disconnect the battery temperature sensor connector. CHECK: Using an ohmmeter, measure the resistance between terminals. OK: Standard resistance: Terminals Resistance (at 25 °C (77°F) 1–2 9 – 11 kΩ 3–4 9 – 11 kΩ 5–6 9 – 11 kΩ 7–8 9 – 11 kΩ 9 – 10 9 – 11 kΩ NG OK Check fitting of battery temperature sensor connector and correct if necessary. 2001 PRIUS (RM778U) Replace the battery temperature sensor. DI–351 DIAGNOSTICS – HV BATTERY CONTROL SYSTEM DI82G–01 DTC P3077 Battery Cooling Fan Motor Circuit Malfunction CIRCUIT DESCRIPTION To control rise in battery temperature during driving and charging, the battery fan operation is controlled in 3 levels depending on battery temperature. DTC No. DTC Detecting Condition Trouble Area Electric error in battery cooling fan motor circuit continues for 10 sec. (2 trip detection logic) P3077
Battery blower motor
Battery fan relay
Battery blower motor controller
Wire harness WIRING DIAGRAM Battery ECU 8 B18 FCTL1 LG – R B19 Battery Fan Relay 7 IH1 L–R 1 2 3 5 L L–B B15 Battery Blower Motor L – B L–R 1 2 4 VM SI 2 L–R L Engine Room J/B BATT FAN 8 1J W–B 2 1B Fusible Link Block No. 1 1 1 F13 F12 C J32 13 3 +B E 2 B18 VM 9 B18 SI 1 B16 W–B Battery Blower Motor Controller B J32 J/C J/C B J33 B B–G Fusible Link Block No. 2 1 F18 W–B MAIN W–B Battery BJ BI A14079 2001 PRIUS (RM778U) DI–352 DIAGNOSTICS – HV BATTERY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check FAN fuse of engine room J/B. Engine Room J/B PREPARATION: Remove the FAN fuse from the engine room J/B. CHECK: Check the continuity of the FAN fuse. OK: Continuity NG FAN Fuse A14084 Check for short in all harness and components connected to FAN fuse. Check that the motor is not locked. If locked, replace the motor. OK 2 Check blower fan relay (See page HV–35). NG Replace the blower fan relay. OK 3 Check blower motor operation. PREPARATION: Remove the blower motor (See page HV–32). CHECK: Apply battery voltage to the power supply terminal of the motor, and check the fan rotation. OK: The fan rotates normally. NG OK Replace battery blower motor controller. 2001 PRIUS (RM778U) Replace the blower motor. DI–353 DIAGNOSTICS – HV BATTERY CONTROL SYSTEM DI82H–01 DTC P3115 HV Battery Current Sensor Malfunction CIRCUIT DESCRIPTION The battery ECU inputs signals from a current sensor in the system main relay and controls the output current. DTC No. P3115 DTC Detecting Condition Trouble Area Failure or open circuit in battery current sensor. (2 trip detection logic)
System main relay (Battery current sensor)
Wire harness WIRING DIAGRAM Battery ECU S8 SMR 6 Y–R 3 B18 V+ 7 Y 4 B18 IB 2 Y–B 10 V+ IB V– B18 V– A14075 2001 PRIUS (RM778U) DI–354 DIAGNOSTICS – HV BATTERY CONTROL SYSTEM INSPECTION PROCEDURE 1 Are there any other codes (besides DTC P3115) being output? YES Go to relevant DTC chart. NO 2 Check for open and short in wire harness between HV ECU terminals (V+, IB V–) and system main relay terminals (6, 7, 2). PREPARATION: (a) Disconnect the connector from the battery ECU. (b) Disconnect the connector from the system main relay. CHECK: Check that the wire harness between the battery ECU and the system main relay is short and open. OK: No short and open NG OK 2001 PRIUS (RM778U) Repair or replace the wire harness. DI–355 DIAGNOSTICS 3 – HV BATTERY CONTROL SYSTEM Check resistance of HV battery current sensor (In system main relay). CHECK: Using an ohmmeter, measure the resistance between terminals. OK: Standard resistance: 2 7 Terminal No. (Tester+) Terminal No. (Tester–) Resistance 6 7 30 – 50 kΩ 6 2 More than 10 MΩ 7 6 30 – 50 kΩ 7 2 More than 10 MΩ 2 6 300 – 400 kΩ 2 7 3 – 5 MΩ 1 6 5 4 3 A15566 NG OK Check fitting of connector S8 of system main relay and correct if necessary. 2001 PRIUS (RM778U) Replace the system main relay. DI–358 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI7OJ–01 PRE–CHECK 1. (a) (b) 2. (a) (b) USA: PRECAUTION To distinguish trouble and repair it, perform necessary electrical shock prevention operation (See page IN–4). Some portions of the wiring harness belong to the 288 V circuit, to which a high voltage is supplied. To avoid receiving an electrical shock, be sure to observe the following: (1) Wear insulating gloves during inspection. (2) Before removing or installing parts and connectors, remove the service plug and conform that the voltage at the output terminals has dropped down to 0 V. (3) When disengaging wiring connectors, hold the connector bodies to avoid pulling the wires. When engaging wiring connectors, be sure to engage them securely. DIAGNOSIS SYSTEM Release the parking brake pedal. Check the indicator. When the ignition switch is turned ON, check that the ABS warning light and BRAKE warning light goes on for approx. 3 seconds. HINT:

CANADA: (c) F12426 HINT: If the warning buzzer check result is not normal, proceed to troubleshooting for the brake warning buzzer circuit (See page DI–444). (d) DLC3 Tc In case of not using TOYOTA hand–held tester: Check the DTC. (1) Using SST, connect terminals Tc and CG of DLC3. SST 09843–18040 (2) Turn the ignition switch ON. (3) Read the DTC from the ABS warning light on the combination meter. HINT: CG F09750 2001 PRIUS (RM778U) When the parking brake is applied or the level of the brake fluid is low, the BRAKE warning light is lit. If the indicator check result is not normal, proceed to troubleshooting for the ABS warning light circuit or BRAKE warning light circuit (See page DI–437 or DI–441). Check the warning buzzer. When depressing the brake pedal repeatedly it may turn on the brake warning buzzer.
If no code appears, inspect the diagnostic circuit or ABS warning light circuit (See page DI–437 or DI–447). DI–359 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS
As an example, the blinking patterns for normal code and codes 11 and 21 are shown on the left. (4) Codes are explained in the code table on page DI–358. (5) After completing the check, disconnect terminals Tc and CG, and turn off the display. If 2 or more malfunctions are indicated at the same time the lowest numbered DTC will be displayed 1st. Normal Code 2 sec. 0.25 sec. 0.25 sec. ON OFF Code 11 and 21 0.5 sec. 1.5 sec. 4 sec. 0.5 sec. 2.5 sec. ON OFF Code 11 Code 21 R01346 TOYOTA Hand–held Tester DLC3 F12396 BR3890 2001 PRIUS (RM778U) (e) In case of using TOYOTA hand–held tester: Check the DTC. (1) Hook up the TOYOTA hand–held tester to the DLC3. (2) Turn the ignition switch ON. (3) Read the DTC by following the prompts on the tester screen. HINT: Please refer to the TOYOTA hand–held tester operator’s manual for further details. (f) In case of not using TOYOTA hand–held tester: Clear the DTC. (1) Using SST, connect terminals Tc and CG of DLC3. SST 09843–18040 (2) Turn the ignition switch ON. (3) Clear the DTC stored in ECU by depressing the brake pedal 8 or more times within 5 seconds. (4) Check that the warning light shows the normal code. (5) Remove the SST from the terminals of DLC3. SST 09843–18040 DI–360 DIAGNOSTICS TOYOTA Hand–held Tester DLC3 F12396 Ts DLC3 Tc CG F09750 0.13 sec. 0.13 sec. ON OFF BR3904 2001 PRIUS (RM778U) (g) – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS In case of using TOYOTA hand–held tester: Clear the DTC. (1) Hook up the TOYOTA hand–held tester to the DLC3. (2) Turn the ignition switch ON. (3) Operate the TOYOTA hand–held tester to erase the codes. HINT: Please refer to the TOYOTA hand–held tester operator’s manual for further details. 3. SENSOR SIGNAL CHECK (TEST MODE) HINT: If the ignition switch is turned from ON to ACC or LOCK during test mode, DTC will be erased. (a) In case of not using TOYOTA hand–held tester: Check the sensor signal. (1) Turn the ignition switch OFF. (2) Using SST, connect terminals Ts and CG of DLC3. SST 09843–18040 (3) Start the engine. (4) Check that the ABS warning light blinks. HINT: If the ABS warning light does not blink, inspect the ABS warning light circuit and Ts terminal circuit (See page DI–437, DI–449). (5) Keep the vehicle in the stationary condition and the brake pedal in free condition for 1 sec. or more. (6) Keeping the vehicle in the stationary condition, depress the brake pedal with 98 N (10 kgf, 22 lbf) or more for 1 sec. or more. (7) Drive vehicle straight forward. When driving the vehicle at the speed faster than 45 km/h (28 mph) for several seconds, check that the ABS warning light comes off. HINT: There is a case that the sensor check is not completed if the vehicle has its front wheels spun or its steering wheel steered during this check. DI–361 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS (8) Stop the vehicle. (9) Using SST, connect terminals Tc and CG of DLC3. SST 09843–18040 (10) Read the number of blinks of the ABS warning light. HINT:


See the list of DTC shown on the next page. If every sensor is normal, a normal code is output (A cycle of 0.25 sec. ON and 0.25 sec. OFF is repeated). If 2 or more malfunctions are indicated at the same time, the lowest numbered code will be displayed 1st. Malfunction Code (Example Code 72, 76) 7 2 7 6 ON OFF 0.5 sec. 1.5 sec. 0.5 sec. 0.5 sec. 2.5 sec. 0.5 sec. 4 sec. Repeat BR3893 (11) After doing the check, turn ignition switch OFF, and disconnect the SST from terminals Ts and CG, Tc and CG of DLC3. SST 09843–18040 TOYOTA Hand–held Tester DLC3 F12396 2001 PRIUS (RM778U) (b) In case of using TOYOTA hand–held tester: Check the DTC. (1) Hook up the TOYOTA hand–held tester to the DLC3. (2) Do step (3) to (8) on the previous page and this page. (3) Read the DTC by following the prompts on the tester screen. HINT: Please refer to the TOYOTA hand–held tester operator’s manual for further details. DI–362 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DTC of sensor check function: Code No. Diagnosis Trouble Area C1271/71 Low output voltage of right front speed sensor
Right front speed sensor
Sensor installation
Right front speed sensor rotor C1272/72 Low output voltage of left front speed sensor
Left front speed sensor
Sensor installation
Left front speed sensor rotor C1273/73 Low output voltage of right rear speed sensor
Right rear speed sensor
Sensor installation
Right rear speed sensor rotor C1274/74 Low output voltage of left rear speed sensor
Left rear speed sensor
Sensor installation
Left rear speed sensor rotor C1275/75 Abnormal change in output voltage of right front speed sensor Right front speed sensor rotor C1276/76 Abnormal change in output voltage of left front speed sensor Left front speed sensor rotor C1277/77 Abnormal change in output voltage of right rear speed sensor Right rear speed sensor rotor C1278/78 Abnormal change in output voltage of left rear speed sensor Left rear speed sensor rotor C1281/81 Master cylinder (M/C) pressure sensor output signals is faulty Master cylinder (M/C) pressure sensor C1282/82 Regulator (REG) pressure sensor output signal is faulty Regulator (REG) pressure sensor C1283/83 Front (FR) pressure sensor output signal is faulty Front (FR) pressure sensor C1284/84 Rear (RR) pressure sensor output signal is faulty Rear (RR) pressure sensor 2001 PRIUS (RM778U) DI–363 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI28U–10 DIAGNOSTIC TROUBLE CODE CHART NOTICE: When removing the part, turn the ignition switch OFF. HINT:
Using SST 09843–18040, connect the terminals Tc and CG of DLC3.
If any abnormality is not found when inspecting parts, inspect the ECU.
If a malfunction code is displayed during the DTC check, check the circuit listed that code. For details of each code, turn to the page referred to under the ”See page” for respective ”DTC No.” in the DTC chart. DTC No. (See Page) Detection Item C0200/31*1 (DI–366) Right front wheel speed sensor signal malfunction C0205/32*1 (DI–366) Left front wheel speed sensor signal malfunction C0210/33*1 (DI–366) Right rear wheel speed sensor signal malfunction C0215/34*1 (DI–366) Left rear wheel speed sensor signal malfunction Trouble Area
Right front, left front, right rear and left rear speed sensor
Each E h speed d sensor circuit i it
Sensor rotor C0226/21 (DI–373) Malfunction in ABS solenoid (SFR) circuit
SFRR or SFRH circuit
Brake actuator C0236/22 (DI–373) Malfunction in ABS solenoid (SFL) circuit
SFLR or SFLH circuit
Brake actuator C0246/23 (DI–373) Malfunction in ABS solenoid (SR) circuit
SRR or SRH circuit
Brake actuator C0278/11 (DI–376) Open circuit in ABS solenoid relay circuit C0279/12 (DI–376) Short circuit in ABS solenoid relay circuit C1202/58 (DI–380) Brake fluid level low Open circuit in brake fluid level warning switch circuit
Brake fluid level
Brake fluid level warning switch
Brake fluid level warning switch circuit C1211/61 (DI–382) Malfunction in linear solenoid (SLA) circuit
SLA+ or SLA– circuit
Brake actuator C1212/62 (DI–382) Malfunction in linear solenoid (SLR) circuit
SLR+ or SLR– circuit
Brake actuator C1213/63 (DI–384) Malfunction in HV ECU communication circuit
HVI+ or HVI– circuit
HVO+ or HVO– circuit
HV ECU C1214/64 (DI–386) Malfunction in hydraulic system
Each pressure sensor
Each pressure sensor circuit
Fluid leakage C1215/15 (DI–387) Low positive voltage of linear solenoid C1216/16 (DI–387) High positive voltage of linear solenoid C1217/25 (DI–373) Malfunction in regenerative solenoid (SMC1) circuit
Regenerative solenoid (SMC1) circuit
Brake actuator C1218/26 (DI–373) Malfunction in regenerative solenoid (SMC2) circuit
Regenerative solenoid (SMC2) circuit
Brake actuator 2001 PRIUS (RM778U)
ABS solenoid relay
ABS solenoid relay circuit
Battery
Charging Ch i system t
Power source circuit DI–364 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS
Regenerative solenoid (SS) circuit
Brake actuator C1219/27 (DI–373) Malfunction in regenerative solenoid (SS) circuit C1220/46 (DI–392) Malfunction in regulator (REG) pressure sensor C1221/46 (DI–392) Malfunction in front (FR) pressure sensor C1222/46 (DI–392) Malfunction in rear (RR) pressure sensor C1241/41 (DI–397) Low or abnormally high battery positive voltage in IG1 circuit
Battery
Charging system
Power source circuit Open circuit in IG2 circuit
Battery
Charging system
Power source circuit C1246/46 (DI–392) Malfunction in master cylinder (M/C) pressure sensor
Master cylinder (M/C) pressure sensor
Master cylinder (M/C) pressure sensor circuit C1249/49 (DI–403) Open circuit in stop light switch circuit
Stop light switch
Stop light switch circuit C1251/51*2 (DI–406) Malfunction in hydraulic brake booster pump motor Hydraulic brake booster pump motor C1252/52*2 (DI–409) Hydraulic brake booster pump motor ON time abnormally long
Hydraulic brake booster pump motor
Hydraulic brake booster pump motor circuit
Pressure switch (PH or PL) C1253/53*2 (DI–416) Malfunction in hydro motor relay circuit
Hydro motor relay
Hydro motor relay circuit C1254/54*2 (DI–421) Malfunction in pressure switch
Pressure switch (PH or PL)
Pressure switch circuit C1256/56*2 (DI–424) Malfunction of accumulator low pressure
Accumulator
Pressure switch (PH or PL)
Hydraulic brake booster pump motor C1257/57*2 (DI–430) Malfunction in power supply drive circuit
Battery
Power Source circuit C1259/59 (DI–433) Malfunction in regenerative of HV ECU
HV control system
HV ECU Malfunction in brake ECU
Battery
Charging system
Power source circuit
Brake ECU C1242/42*2 (DI–400) Always ON (DI–434)
Each pressure sensor
Each pressure sensor circuit
Brake actuator *1: As the DTC cannot be erased by replacing parts alone do either of the following operations. (1) Clear DTC (See page DI–353). (2) At the vehicle speed of 20 km/h (12 mph), drive the vehicle for 30 sec. or more. *2: Using the following table, troubled parts can be specified. 2001 PRIUS (RM778U) DI–365 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Table of Trouble Part and DTC: DTC C1242/42 C1251/51 C1252/52 C1253/53 C1254/54 C1256/56 C1257/57 BRAKE warning light and buzzer Pressure switch Light Light Buzzer PH   PL   Light  Pump motor Pump motor circuit Buzzer Buzzer   MTT wire harness Light  ECU Light Buzzer             Light Buzzer  MR1 open circuit  MR2 open circuit  MR1 welded contact    MR2 welded contact       Power suplly circuit *: When IG1 circuit is open, ABS warning light and BRAKE warning light come on. 2001 PRIUS (RM778U) Buzzer  Accumulator malfunction Hydraulic brake booster Pressure leaks Power source* IG2 open circuit Light  MT+ wire harness MT– wire harness Motor relay circuit Buzzer  DI–367 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI1GG–06 TERMINALS OF ECU B10 B12 B11 B13 F02094 Symbols (Terminals No.) Wiring Color Condition SFRH (B10 – 1) – GND (B10 – 6, 31, B11 – 8, 17) R–B ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SFRR (B10 – 2) – GND (B10 – 6, 31, B11 – 8, 17) R–W ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SMC2 (B10 – 3) – GND (B10 – 6, 31, B11 – 8, 17) G–B ↔ W–B IG switch ON, ABS warning light OFF (Brake pedal released) 10 – 14 SMC1 (B10 – 4) – GND (B10 – 6, 31, B11 – 8, 17) G–W ↔ W–B IG switch ON, ABS warning light OFF (Brake pedal released) 10 – 14 SS (B10 – 5) – GND (B10 – 6, 31, B11 – 8, 17) G–O ↔ W–B IG switch ON, ABS warning light OFF (Brake pedal released) 10 – 14 SFLR (B10 – 7) – GND (B10 – 6, 31, B11 – 8, 17) R–G ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SRRH (B10 – 8) – GND (B10 – 6, 31, B11 – 8, 17) R–Y ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SRRR (B10 – 9) – GND (B10 – 6, 31, B11 – 8, 17) R–L ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 VCM (B10 – 10) – GND (B10 – 6, 31, B11 – 8, 17) B ↔ W–B IG switch ON 4.5 – 5.5 PH (B10 – 11) – GND (B10 – 6, 31, B11 – 8, 17) GR ↔ W–B W B SG1 (B10 – 12) – GND (B10 – 6, 31, B11 – 8, 17) Shielded ↔ W–B FR+ (B10 – 14) – FR– (B10 – 13) P↔L IG switch ON, slowly turn right front wheel Pulse generation FL+ (B10 – 16) – FL– (B10 – 15) R↔G IG switch ON, slowly turn left front wheel Pulse generation MT– (B10 – 18) – GND (B10 – 6, 31, B11 – 8, 17) Y ↔ W–B SR (B10 – 19) – GND (B10 – 6, 31, B11 – 8, 17) Vehicle stops, pump motor rotates STD Voltage (V) 5–7 Vehicle stops, pump motor stops Below 1.0 IG switch OFF Continuity IG switch OFF Continuity B–L ↔ W–B IG switch ON, ABS warning light OFF Below 1.5 SFLH (B10 – 21) – GND (B10 – 6, 31, B11 – 8, 17) Y–B ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 PMC (B10 – 22) – GND (B10 – 6, 31, B11 – 8, 17) W ↔ W–B IG switch ON, stop light switch OFF Below 1.0 E2 (B10 – 23) – GND (B10 – 6, 31, B11 – 8, 17) R ↔ W–B IG switch OFF Continuity FSS (B10 – 24) – GND (B10 – 6, 31, B11 – 8, 17) BR ↔ W–B IG switch OFF Continuity 2001 PRIUS (RM778U) DI–368 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS IG switch ON, pump motor rotates Above 8.0 IG switch ON, pump motor stops Below 1.5 IG switch ON (Motor relay is OFF) Below 1.5 MTT (B10 – 27) – GND (B10 – 6, 31, B11 – 8, 17) W L ↔ W–B W–L W B MT+ (B10 – 28) – GND (B10 – 6, 31, B11 – 8, 17) Y–G ↔ W–B MR1 (B10 – 29) – GND (B10 – 6, 31, B11 – 8, 17) LG–R ↔ W–B STP (B11 – 1) – GND (B10 – 6, 31, B11 – 8, 17) G W ↔ W–B G–W W B SP1 (B11 – 2) – GND (B10 – 6, 31, B11 – 8, 17) V–R ↔ W–B Vehicle driving at about 30 km/h (19 mph) Tc (B11 – 3) – GND (B10 – 6, 31, B11 – 8, 17) P–B ↔ W–B IG switch ON 10 – 14 Ts (B11 – 4) – GND (B10 – 6, 31, B11 – 8, 17) GR–G ↔ W–B IG switch ON 10 – 14 IG switch ON, ABS motor stops 10 – 14 Stop light switch OFF Below 1.5 Stop light switch ON 8 – 14 Pulse generation BRL (B11 – 5) – GND (B10 – 6, 31, B11 – 8, 17) R–Y ↔ W–B IG switch OFF → ON (Parking brake switch OFF) IG1 (B11 – 6) – GND (B10 – 6, 31, B11 – 8, 17) B–Y ↔ W–B IG switch ON 10 – 14 R1+ (B11 – 7) – GND (B10 – 6, 31, B11 – 8, 17) Y–B ↔ W–B IG switch ON 10 – 14 D/G (B11 – 10) – GND (B10 – 6, 31, B11 – 8, 17) W–L ↔ W–B IG switch ON 10 – 14 RR+ (B11 – 11) – RR– (B11 – 12) Y ↔ BR HVO+ (B11 – 14) – GND (B10 – 6, 31, B11 – 8, 17) G ↔ W–B IG switch ON RLO (B11 – 15) – GND (B10 – 6, 31, B11 – 8, 17) W ↔ W–B Vehicle driving at about 30 km/h (19 mph) HVI– (B11 – 16) – GND (B10 – 6, 31, B11 – 8, 17) V ↔ W–B IG switch ON WA (B11 – 18) – GND (B10 – 6, 31, B11 – 8, 17) B W ↔ W–B B–W W B RL+ (B11 – 19) – RL– (B11 – 20) RSS (B11 – 21) – GND (B10 – 6, 31, B11 – 8, 17) P↔L IG switch ON, slowly turn right rear wheel 10 – 14 for about 3 sec., then Below 2 Pulse generation About 2.5 Pulse generation About 2.5 IG switch ON, ABS warning light ON 10 – 14 IG switch ON, ABS warning light OFF Below 2.0 IG switch ON, slowly turn left rear wheel Pulse generation BR–B ↔ W–B IG switch OFF Continuity HVO– (B11 – 22) – GND (B10 – 6, 31, B11 – 8, 17) R ↔ W–B IG switch ON About 2.5 RRO (B11 – 23) – GND (B10 – 6, 31, B11 – 8, 17) B ↔ W–B Vehicle driving at about 30 km/h (19 mph) HVI+ (B11 – 24) – GND (B10 – 6, 31, B11 – 8, 17) LG ↔ W–B IG switch ON About 2.5 IG2 (B12 – 1) – GND (B10 – 6, 31, B11 – 8, 17) B–W ↔ W–B IG switch ON 10 – 14 LBL (B12 – 7) – GND (B10 – 6, 31, B11 – 8, 17) LG–R ↔ W–B IG switch ON, fluid in master cylinder reservoir above MIN level 4.5 – 6.4 VFR (B12 – 9) – GND (B10 – 6, 31, B11 – 8, 17) B ↔ W–B IG switch ON 4.5 – 5.5 PKB (B12 – 13) – GND (B10 – 6, 31, B11 – 8, 17) R Y ↔ W–B R–Y W B IG switch ON, parking brake switch ON Below 1.5 IG switch ON, parking brake switch OFF 10 – 14 2001 PRIUS (RM778U) Pulse generation DI–369 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS SG2 (B12 – 15) – GND (B10 – 6, 31, B11 – 8, 17) Shielded ↔ W–B IG switch OFF Continuity VREG (B12 – 16) – GND (B10 – 6, 31, B11 – 8, 17) B ↔ W–B IG switch ON 4.5 – 5.5 SG3 (B12 – 18) – GND (B10 – 6, 31, B11 – 8, 17) Shielded ↔ W–B IG switch OFF Continuity BZ (B12 – 20) – GND (B10 – 6, 31, B11 – 8, 17) G ↔ W–B W B IG switch ON, buzzer sounds Below 1.5 EREG (B12 – 24) – GND (B10 – 6, 31, B11 – 8, 17) R ↔ W–B IG switch OFF Continuity PREG (B12 – 25) – GND (B10 – 6, 31, B11 – 8, 17) W ↔ W–B IG switch ON, brake pedal released Below 1.0 EFR (B12 – 27) – GND (B10 – 6, 31, B11 – 8, 17) R ↔ W–B IG switch OFF Continuity PFR (B12 – 28) – GND (B10 – 6, 31, B11 – 8, 17) W ↔ W–B IG switch ON, brake pedal released Below 1.0 SLA+ (B13 – 1) – GND (B10 – 6, 31, B11 – 8, 17) L ↔ W–B IG switch ON MR2 (B13 – 2) – GND (B10 – 6, 31, B11 – 8, 17) Y G ↔ W–B Y–G W B R2+ (B13 – 3) – GND (B10 – 6, 31, B11 – 8, 17) IG switch ON, buzzer does not sound IG switch ON, pump motor rotates 10 – 14 Pulse generation Below 1.0 IG switch ON, pump motor stops 10 –14 L–O ↔ W–B IG switch ON 10 – 14 VRR (B13 – 5) – GND (B10 – 6, 31, B11 – 8, 17) B ↔ W–B IG switch ON 4.5 – 5.5 AST (B13 – 6) – GND (B10 – 6, 31, B11 – 8, 17) B–O ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SLR– (B13 – 7) – GND (B10 – 6, 31, B11 – 8, 17) V ↔ W–B IG switch ON Below 1.5 SLA– (B13 – 8) – GND (B10 – 6, 31, B11 – 8, 17) LG ↔ W–B IG switch ON Below 1.5 PL (B13 – 9) – GND (B10 – 6, 31, B11 – 8, 17) Y–R ↔ W–B PRR (B13 – 13) – GND (B10 – 6, 31, B11 – 8, 17) W ↔ W–B IG switch ON, brake pedal released SLR+ (B13 – 16) – GND (B10 – 6, 31, B11 – 8, 17) P ↔ W–B IG switch ON Pulse generation SG4 (B13 – 19) – GND (B10 – 6, 31, B11 – 8, 17) Shielded ↔ W–B IG switch OFF Continuity ERR (B13 – 20) – GND (B10 – 6, 31, B11 – 8, 17) R ↔ W–B IG switch OFF Continuity +BS (B13 – 22) – GND (B10 – 6, 31, B11 – 8, 17) L ↔ W–B IG switch ON 10 – 14 2001 PRIUS (RM778U) IG switch OFF, depress brake pedal more than 40 times → IG switch ON 6.5 – 10 → 2.5 – 5.0 Below 1.0 DI–371 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI7OK–01 CIRCUIT INSPECTION DTC C0200/31 – C0215/34 Speed Sensor Circuit CIRCUIT DESCRIPTION Rotor The speed sensor detects wheel speed and sends the appropriate signals to the ECU. These signals are used for control of both the ABS & EBD control system. The front and rear rotors each have 48 serrations. When the rotors rotate, the magnetic field emitted by the permanent magnet in the speed sensor generates an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. Speed Sensor S Magnet N Coil To ECU Low Speed High Speed +V BR3583 BR3582 –V F00010 DTC No. DTC Detecting Condition C0200/31 C0205/32 C0210/33 C0215/34 Detection of any of conditions 1. through 4.: 1. At vehicle speed of 10 km/h (6 mph) or more, pulses are not input for 15 sec. or more. 2. While a vehicle is driven at a speed of 15 km/h (24 mph) or more, pulse signals from the speed sensor are instantly omitted 7 times or more. 3. While a vehicle is driven at a speed of 20 km/h (32 mph) or more, error signals from the speed sensor are transmitted consecutively 75 time or more within 5 min. 4. When the ignition switch is ON, an open circuit in the speed sensor continues for 0.5 sec. or more. HINT: DTC No. DTC No. DTC No. DTC No. C0200/31 C0205/32 C0210/33 C0215/34 2001 PRIUS (RM778U) is is is is for for for for the right front speed sensor. the left front speed sensor. the right rear speed sensor. the left rear speed sensor. Trouble Area
Right front, left front, right rear and left rear speed sensor
Each speed sensor circuit
Sensor rotor DI–372 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS WIRING DIAGRAM Brake ECU A4 Speed Sensor Front LH (Shielded) R 2 16 B10 FL+ 15 B10 FL– G 1 24 B10 FSS BR (Shielded) A5 Speed Sensor Front RH 2 P 14 B10 FR+ L 13 B10 FR– 1 5 IB1 (Shielded) (Shielded) 1 A23 Speed Sensor Rear LH P 1 IB1 P 19 B11 RL+ L 2 IB1 L 20 B11 RL– 2 (Shielded) A24 Speed Sensor Rear RH 1 BR–B 21 B11 RSS Y 11 B11 RR+ BR 12 B11 RR– 2 (Shielded) F12670 2001 PRIUS (RM778U) DI–373 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS INSPECTION PROCEDURE HINT: Start the inspection from step 1 in case of using the TOYOTA hand–held tester and start from step 2 in case of not using the TOYOTA hand–held tester. 1 Check output value of speed sensor. PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON, and push the TOYOTA hand–held tester main switch ON. (c) Select the DATALIST mode on the TOYOTA hand–held tester. CHECK: Check that there is no difference between the speed value output from the speed sensor displayed on the TOYOTA hand–held tester and the speed value displayed on the speedometer when driving the vehicle. OK: There is almost no difference from the displayed speed value. HINT: There is tolerance of ± 10 % in the speedometer indication. OK Check and replace brake ECU. NG 2 Check speed sensor. 1 2 R14205 2001 PRIUS (RM778U) Front: PREPARATION: (a) Remove the front fender liner. (b) Make sure that there is no looseness at the connector lock part and connecting part of the connector. (c) Disconnect the speed sensor connector. CHECK: Measure resistance between terminals 1 and 2 of speed sensor connector. OK: Resistance: 0.6 – 2.5 kΩ CHECK: Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. OK: Resistance: 10 MΩ or higher DI–374 DIAGNOSTICS 1 2 F10179 Connector 1 1 2 1 Connector 2 2 F10180 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Rear: PREPARATION: (a) Make sure that there is no looseness at the connector lock part and connecting part of the connector. (b) Disconnect the speed sensor connector at hub bearing . CHECK: Measure resistance between terminals 1 and 2 of speed sensor connector. OK: Resistance: 0.7 – 2.2 kΩ CHECK: Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. OK: Resistance: 1 MΩ or higher Rear speed sensor sub–wire harness: PREPARATION: (a) Remove the seat cushion and seatback. (b) Make sure that there is no looseness at the connector lock part and connecting part of the connector. (c) Disconnect the speed sensor connector inside vehicle. CHECK: (a) Measure resistance between terminal 1 of connector 1 and terninal 2 of connector 2. (b) Measure resistance between terminal 2 of connector 1 and terninal 1 of connector 2. OK: Resistance: below 1 Ω CHECK: Measure resistance between terminals 1 and 2 of speed sensor connector 1 and body ground. OK: Resistance: 10 MΩ or higher NG Replace speed sensor or sub–wire harness. NOTICE: Check the speed sensor signal last (See page DI–353). OK 2001 PRIUS (RM778U) DI–375 DIAGNOSTICS 3 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check for open and short circuit in harness and connector between each speed sensor and brake ECU (See page IN–41). NG Repair or replace harness or connector. OK 4 Check speed sensor installation. CHECK: Check the speed sensor installation. OK: The installation bolt is tightened properly and there is no clearance between the sensor and steering knuckle or rear axle carrier. Torque: Front speed sensor : 8.0 N·m (82 kgf·cm, 71 in.·lbf) Front OK NG Rear BR3795 F10178 OK NG F10452 NG Replace speed sensor. NOTICE: Check the speed sensor signal last (See page DI–353). OK 2001 PRIUS (RM778U) DI–376 DIAGNOSTICS 5 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check speed sensor and sensor rotor serrations. Normal Signal Waveform GND 2 m/s / Division 1 V / Division W04200 REFERENCE: INSPECTION USING OSCILLOSCOPE PREPARATION: (a) Remove the brake ECU with connectors still connected. (b) Connect the oscilloscope to the terminals FR+, FL+, RR+ or RL+ and GND of the brake ECU. CHECK: Drive the vehicle with about 20 km/h (12 mph), and check the signal waveform. HINT:
As the vehicle speed (rpm of the wheels) increases, a cycle of the waveform becomes shorter and the fluctuation in the output voltage becomes greater.
When noise is identified in the waveform on the oscilloscope, error signals are generated due to the speed sensor rotor’s scratches, looseness or foreign matter deposited on it. OK Check and replace brake ECU. NG 6 Check sensor rotor and sensor tip. R00948 2001 PRIUS (RM778U) Front: PREPARATION: Remove the front drive shaft (See page SA–17). CHECK: Check the sensor rotor serrations. OK: No scratches or missing teeth or foreign objects. PREPARATION: Remove the front speed sensor (See page BR–53). CHECK: Check the sensor tip. OK: No scratches or foreign objects on the sensor tip. HINT: If foreign matter (including that on the sensor rotor side) is identified, remove it and after reassembling, check the output waveform. DI–377 DIAGNOSTICS W04846 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Rear: PREPARATION: Remove the rear speed sensor (See page BR–56). CHECK: Check the sensor rotor serrations. OK: No scratches or missing teeth or foreign objects. HINT: If the sensor rotor is damaged or deformed, replace the hub assembly. CHECK: Check the sensor tip. OK: No scratches or foreign objects on the sensor tip. HINT: If foreign matter (including that on the sensor rotor side) is identified, remove it and after reassembling, check the output waveform. NG Replace sensor rotor or speed sensor. NOTICE: Check the speed sensor signal last (See page DI–353). OK Check and replace brake ECU. 2001 PRIUS (RM778U) DI–378 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI28Z–13 DTC C0226/21 – C0246/23 ABS Solenoid Circuit DTC C1217/25 – C1219/27 Regenerative Solenoid Circuit CIRCUIT DESCRIPTION This solenoid goes on when signals are received from the ECU and controls the pressure acting on the wheel cylinders thus controlling the braking force. DTC No. DTC Detecting Condition C0226/21 Open or short circuit in SFRH or SFRR circuit continues for 0.05 sec. or more.
SFRH or SFRR circuit
Brake actuator C0236/22 Open or short circuit in SFLH or SFLR circuit continues for 0.05 sec. or more.
SFLH or SFLR circuit
Brake actuator C0246/23 Open or short circuit in SRR or SRH circuit continues for 0.05 sec. or more.
SRR or SRH circuit
Brake actuator C1217/25 Open or short circuit in SMC1 circuit continues for 0.05 sec. or more.
SMC1 circuit
Brake actuator C1218/26 Open or short circuit in SMC2 circuit continues for 0.05 sec. or more.
SMC2 circuit
Brake actuator C1219/27 Open or short circuit in SS circuit continues for 0.05 sec. or more.
SS circuit
Brake actuator 2001 PRIUS (RM778U) Trouble Area DI–379 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS WIRING DIAGRAM Y–B W–R 2 4 1 Engine Room R/B No. 3 Y–B Brake ECU 7 B11 R1+ 3 3 3 14 IA2 Engine Room R/B No. 3 2 3 ABS No. 1 ABS Solenoid Relay 1 6 3 3 3 W–B A W J7 J/C A F10 1 FL Block No. 1 W–B DC/DC F13 1 A J1 J/C B–G 1 3 B2 1 Brake Actuator BS 9 SFRH B3 2 B10 SFRR R–W SFLH 10 B3 Y–B SFLR 2 B2 R–G SRRR IE 1 B10 SFRH 5 B3 MAIN Battery R–B SFRR SRRH FL Block No. 2 19 B10 SR B–L R 12 B3 3 B2 21 B10 SFLH 7 B10 SFLR R–Y 8 B10 SRRH R–L 9 B10 SRRR SMC1 4 B3 G–W 4 B10 SMC1 SMC2 11 B3 G–B 3 B10 SMC2 SS 3 B3 G–O 5 B10 SS F12671 2001 PRIUS (RM778U) DI–380 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS INSPECTION PROCEDURE 1 Check brake actuator solenoid. SMC1 SFRR SS SFRH BS SFLR SRRH SMC2 SFLH SRRR F12666 PREPARATION: Disconnect the 2 connectors from the brake actuator. CHECK: Check continuity between the terminal BS and each of terminals SFRH, SFRR, SFLH, SFLR, SRRH, SRRR, SMC1, SMC2 and SS of brake actuator connector. OK: Continuity HINT: Resistance of each solenoid at 20 °C (68 °F) SFRH, SFLH, SRRH: approx. 6.6 Ω SFRR, SFLR, SRRR: approx. 2.2 Ω SMC1, SMC2, SS: approx. 16 Ω NG Replace brake actuator. OK 2 Check for open and short circuit in harness and connector between brake ECU and brake actuator (See page IN–41). NG Repair or replace harness or connector. OK If the same code is still output after the DTC is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. 2001 PRIUS (RM778U) DI–381 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI290–08 DTC ABS Solenoid Relay Circuit C0278/11, C0279/12 CIRCUIT DESCRIPTION This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on. DTC No. DTC Detecting Condition Trouble Area When the terminal SR in brake ECU is 2 V or less, the terminal AST in brake ECU continues to be in other than the range from 10 – 14 V for 0.2 sec. more. C0278/11 When the voltage of the terminal SR in brake ECU is 10 – 14 V, the terminal AST in brake ECU continues to be in the range from 10 – 14 V for 0.2 sec. more. C0279/12
ABS solenoid relay
ABS solenoid relay circuit WIRING DIAGRAM Engine Room R/B No. 3 ABS No. 1 W 3 3 1 Brake ECU W–R 2 3 2 3 F13 1 1 FL Block No. 2 B–G MAIN Battery 7 B11 R1+ Engine Room R/B No. 3 4 1 DC/DC Y–B 3 F10 1 FL Block No. 1 14 B1 Y–B ABS Solenoid Relay 3 A A A W–B J7 J/C W–B J1 J/C 6 3 3 19 B10 SR B–L R B2 1 Brake Actuator BS Brake ECU IE AST 6 B3 B–O 6 B13 AST F12672 2001 PRIUS (RM778U) DI–382 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS INSPECTION PROCEDURE HINT: Start the inspection from step 1 in case of using the TOYOTA hand–held tester and start from step 2 in case of not using the TOYOTA hand–held tester. 1 Check ABS solenoid relay operation. PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON, and push the TOYOTA hand–held tester main switch ON. (c) Select the ACTIVE TEST mode on the TOYOTA hand–held tester. CHECK: Check the operation sound of the ABS solenoid relay when operating it with the TOYOTA hand–held tester. OK: The operation sound of the ABS solenoid relay should be heard. OK Go to step 4. NG 2 Check voltage between terminals 1 and 2 of engine room R/B No. 3 (for ABS solenoid relay). Engine Room R/B No. 3 LOCK 2 1 PREPARATION: Remove the ABS solenoid relay from engine room R/B No. 3. CHECK: Measure the voltage between terminals 1 and 2 of engine room R/B No. 3 (for ABS solenoid relay). OK: Voltage: 10 – 14 V F12662 NG OK 2001 PRIUS (RM778U) Check and repair harness or connector. DI–383 DIAGNOSTICS 3 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check ABS solenoid relay. 3 6 Open 2 5 CHECK: Check continuity between each terminal of ABS solenoid relay. OK: 1 4 3 2 1 6 5 4 Terminals 4 and 6 Continuity (Reference value 80 Ω) Terminals 2 and 3 Continuity Terminals 1 and 3 Open Continuity CHECK: (a) Apply battery positive voltage between terminals 4 and 6. (b) Check continuity between each terminal of ABS solenoid relay. OK: Continuity Continuity 3 2 1 Terminals 2 and 3 Open Terminals 1 and 3 Continuity Open (–) 6 5 4 (+) F00042 NG OK 2001 PRIUS (RM778U) Replace ABS solenoid relay. DI–384 DIAGNOSTICS 4 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check continuity between terminals 3 of engine room R/B No. 3 (for ABS solenoid relay) and terminal AST of brake ECU. Engine Room R/B No. 3 ABS Solenoid Relay 3 BS Brake Actuator CHECK: Check continuity between terminal 3 of engine room R/B No. 3 (for ABS solenoid relay) and terminal AST of brake ECU. OK: Continuity HINT: There is a resistance of approx. 33 Ω between terminals BS and AST of the brake actuator. AST AST Brake ECU AST F12443 NG Repair or replace harness or brake actuator. OK 5 Check for open and short circuit in harness and connector between ABS solenoid relay and brake ECU (See page IN–41). NG Repair or replace harness or connector. OK If the same code is still output after the DTC is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. 2001 PRIUS (RM778U) DI–385 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI1GZ–10 DTC C1202/58 Brake Fluid Warning Switch Circuit CIRCUIT DESCRIPTION The brake fluid level warning switch sends the appropriate signal to the ECU when the brake fluid level drops. HINT: Depressing the parking brake pedal also turns on the brake warning light but does not diagnose DTC No. C1202/58. DTC No. DTC Detecting Condition Trouble Area C1202/58 When any of the following 1. 2. or 3. is detected: 1. When the ignition switch is ON, an open condition in the reservoir level switch circuit continues for 2 sec. or more. 2. While a vehicle is driven at a speed of 3 km/h (5 mph) or more, decrease in the reservoir level continues for 10 sec. or more. 3. While a vehicle is stopped, decrease in the reservoir level continues for 5 sec. or more.
Brake fluid level
Brake fluid level warning switch
Brake fluid level warning switch circuit WIRING DIAGRAM B–G Instrument Panel J/B FL Block No. 1 1 1 DC/DC F13 F11 Body ECU Ignition Switch 15 B8 16 B8 W GR–B L 2 4 B–Y W–G 6 2D 3 2B 1 2H 5 2A Brake ECU 2 5 R–Y B11 2K BRL 4 GR Multiplex Communication Circuit 7 B12 LBL C10 22 C11 2 C11 3 AM1 FL Block 1 No. 2 MAIN 1 5 GAUGE IG1 Relay A L 14 C10 6 2B J11 J/C Combination Meter Instrument Panel J/B W–B ID Brake 7 2A 3 2 8 2K Battery LG–R W–B A A BR IH IE J1 J/C W–B A 1 J7 J/C 2 Brake Fluid Level Warning Switch F12673 2001 PRIUS (RM778U) DI–386 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS INSPECTION PROCEDURE 1 Check brake fluid level. CHECK: Check the amount of fluid in the brake reservoir. NG Check and repair brake fluid leakage and add fluid. OK 2 Check brake fluid level warning switch (See page BE–2). NG Replace brake fluid level warning switch. OK 3 Check for open circuit in all the harness and components connected to brake fluid level warning light (See page IN–41). NG OK Check and replace brake ECU. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–387 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI7OL–01 DTC C1211/61, C1212/62 Linear Solenoid Circuit CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area C1211/61 When the ignition switch is ON, an open o en or short circuit of solenoid continues for 0.1 sec. or more. C1212/62
SLA+ or SLA– circuit
Brake actuator
SLR+ or SLR– circuit
Brake actuator WIRING DIAGRAM Brake ECU Brake Actuator 2 B3 L 1 B13 SLA+ 1 B3 LG 8 B13 SLA– 8 B3 P 16 B13 SLR+ 7 B3 V 7 B13 SLR– F12674 2001 PRIUS (RM778U) DI–388 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS INSPECTION PROCEDURE 1 Check brake actuator solenoid. B3 SLA– SLA+ SLR+ SLR– F10936 PREPARATION: Disconnect the connector (B3) from the brake actuator. CHECK: Check continuity between each of terminals SLA+ and SLA–, and terminals SLR+ and SLR– of brake actuator. OK: Continuity HINT: Resistance of each solenoid approx. 2.3 Ω at 20 °C (68 °F). NG Replace brake actuator. OK 2 Check for open and short circuit in harness and connector between brake ECU and brake actuator (See page IN–41). NG Repair or replace harness or connector. OK If the same code is still output after the DTC is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. 2001 PRIUS (RM778U) DI–389 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI1H0–10 DTC C1213/63 HV ECU Communication Circuit Malfunction CIRCUIT DESCRIPTION The circuit is used to send RBS control information from the brake ECU to the HV ECU (HVI+, HVI–), and HV control information from the HV ECU to the ABS ECU (HVO+, HVO–). DTC No. C1213/63 DTC Detecting Condition Trouble Area When the ignition switch is ON, abnormal communication with HV ECU continues for 0.5 sec. or more.
HVI+ or HVI– circuit
HVO+ or HVO– circuit
HV ECU WIRING DIAGRAM HV ECU Brake ECU (Shielded) LG 20 HTB+ H14 30 HTB– H14 24 B11 HVI+ 16 B11 HVI– V W–B 18 BTH+ H14 17 BTH– H14 (Shielded) G R J11 J/C A W–B A A 14 B11 HVO+ 22 B11 HVO– A W–B J10 J/C ID F12675 2001 PRIUS (RM778U) DI–390 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS INSPECTION PROCEDURE 1 Check for open and short circuit in harness and connector between terminals HVI+, HVI–, HVO+ and HVO– of brake ECU and HV ECU (See page IN–41). NG OK Check and replace HV ECU or brake ECU. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–392 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI7ON–01 DTC C1215/15, C1216/16 Linear Solenoid Positive Voltage Malfunction CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area C1215/15 When any of the following 1. or 2. is detected: 1. When the ignition switch is ON, the condition that the voltage of the terminal +BS in brake ECU is 2.5 V or less continues for 0.5 sec. or more. 2. While a vehicle is driven at a speed of 3 km/h (5 mph) or more, the condition that the voltage of the terminal +BS in brake ECU is 9 V or less continues for 10 sec. or more. C1216/16 When the ignition switch is ON, the condition that the voltage of the terminal +BS in brake ECU is 17 V or more continues for 1.2 sec. or more.
Battery
Charging system
Power source circuit WIRING DIAGRAM Engine Room R/B No. 3 FL Block No. 1 1 F13 B–G DC/DC 1 F10 W ABS No. 4 3 1 3 2 Brake ECU L 22 B13 +BS 1 FL Block No. 2 MAIN 2 B3 L 1 B13 SLA+ 1 B3 LG 8 B13 SLA– 8 B3 P 16 B13 SLR+ 7 B3 V 7 B13 SLR– Battery Brake Actuator 2001 PRIUS (RM778U) F12676 DI–393 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS INSPECTION PROCEDURE 1 Check ABS No. 4 fuse. PREPARATION: Remove the ABS No. 4 fuse from engine room R/B No. 3. CHECK: Check continuity of ABS No. 4 fuse. OK: Continuity Engine Room R/B No. 3 ABS No. 4 F12445 NG Check for short circuit in all the harness and components connected to ABS No. 4 fuse (See attached wiring diagram). NG Check and repair the charging system (See page HV–39). OK 2 Check battery positive voltage. OK: Voltage: 10 – 14 V OK 2001 PRIUS (RM778U) DI–394 DIAGNOSTICS 3 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check voltage of the ECU +BS power source. In case of using the TOYOTA hand–held tester: PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON, and push the TOYOTA hand–held tester main switch ON. (c) Select the DATALIST mode on the TOYOTA hand–held tester. CHECK: Check the voltage condition output from the ECU displayed on the TOYOTA hand–held tester. OK: ”Normal” is displayed. GND In case of not using TOYOTA hand–held tester: PREPARATION: Remove the ABS ECU with connectors still connected. CHECK: Measure voltage between terminals +BS and GND of ABS ECU connector. OK: Voltage: 10 – 14 V +BS F10937 OK Check and replace brake ECU. NG 4 Check for open circuit (to +BS) in harness and connector between brake ECU and battery (See page IN–41). NG OK 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–395 DIAGNOSTICS 5 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check continuity between terminal GND of brake ECU connector and body ground. PREPARATION: Disconnect the 2 connectors (B10, B11) from the brake ECU. CHECK: Measure resistance between terminals GND of brake ECU harness side connector and body ground. OK: Resistance: 1 Ω or less LOCK B10 B11 GND F12406 NG Repair or replace harness or connector. OK 6 Check brake actuator solenoid. B3 SLA– SLA+ SLR+ SLR– F10936 PREPARATION: Disconnect the connector (B3) from the brake actuator. CHECK: Check continuity between each of terminals SLA+ and SLA–, and terminals SLR+ and SLR– of brake actuator. OK: Continuity HINT: Resistance of each solenoid approx. 2.3 Ω at 20 °C (68 °F). NG OK 2001 PRIUS (RM778U) Replace brake actuator. DI–396 DIAGNOSTICS 7 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check for short circuit in harness and connector between brake ECU and brake actuator (See page IN–41). NG OK Check and replace brake ECU. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–397 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI296–06 DTC C1220–C1222/C1246/46 Each Hydraulic Pressure Sensor Circuit CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition C1220/46 Either of the following 1. or 2. is detected: 1. When the ignition switch is ON, the condition that the voltage of the terminal PREG in brake ECU is 0.14 V or less or 4.85 V or more, or that of terminal VREG is 4.4 V or less or 5.6 V or more continues for 1.2 sec. or more. 2. At a vehicle speed of 15 km/h (24 mph) or more, when both the brake switch and hydro motor are OFF, the voltage ratio of the terminal PREG to VREG of brake ECU is 0.06 or less or 0.14 or more continues for 8 sec. and this condition occurs consecutively 10 times.
Regulator (REG) pressure sensor
Regulator (REG) pressure sensor circuit
Brake actuator C1221/46 Either of the following 1. or 2. is detected: 1. When the ignition switch is ON, the condition that the voltage of the terminal PFR in brake ECU is 0.14 V or less or 4.85 V or more, or that of terminal VFR is 4.4 V or less or 5.6 V or more continues for 1.2 sec. or more. 2. At a vehicle speed of 15 km/h (24 mph) or more, when both the brake switch and hydro motor are OFF, the voltage ratio of the terminal PFR to VFR of brake ECU is 0.06 or less or 0.14 or more continues for 8 sec. and this condition occurs consecutively 10 times.
Front (FR) pressure sensor
Front (FR) pressure sensor circuit
Brake actuator C1222/46 Either of the following 1. or 2. is detected: 1. When the ignition switch is ON, the condition that the voltage of the terminal PRR in brake ECU is 0.14 V or less or 4.85 V or more, or that of terminal VRR is 4.4 V or less or 5.6 V or more continues for 1.2 sec. or more. 2. At a vehicle speed of 15 km/h (24 mph) or more, when both the brake switch and hydro motor are OFF, the voltage ratio of the terminal PRR to VRR of brake ECU is 0.06 or less or 0.14 or more continues for 8 sec. and this condition occurs consecutively 10 times.
Rear (RR) pressure sensor
Rear (RR) pressure sensor circuit
Brake actuator C1246/46 Either of the following 1. or 2. is detected: 1. When the ignition switch is ON, the condition that the voltage of the terminal PMC in brake ECU is 0.14 V or less or 4.85 V or more, or that of terminal VMC is 4.4 V or less or 5.6 V or more continues for 1.2 sec. or more. 2. At a vehicle speed of 15 km/h (24 mph) or more, when both the brake switch and hydro motor are OFF, the voltage ratio of the terminal PMC to VMC of brake ECU is 0.06 or less or 0.14 or more continues for 8 sec. and this condition occurs consecutively 10 times.
Master cylinder (M/C) pressure sensor
Master cylinder (M/C) pressure sensor circuit
Brake actuator 2001 PRIUS (RM778U) Trouble Area DI–398 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS WIRING DIAGRAM Brake Actuator Brake ECU 20 B13 ERR 2 B1 R 6 B1 W 13 B13 PRR 10 B1 B 5 B13 VRR (Shielded) 19 B13 SG4 3 B1 R 27 B12 EFR 7 B1 W 28 B12 PFR 11 B1 B 9 B12 VFR (Shielded) 18 B12 SG3 4 B1 R 24 B12 EREG 8 B1 W 25 B12 PREG 12 B1 B 16 B12 VREG (Shielded) 15 B12 SG2 1 B1 R 23 B10 E2 5 B1 W 22 B10 PMC 9 B1 B 10 B10 VCM (Shielded) 12 B10 SG1 F12677 2001 PRIUS (RM778U) DI–399 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS INSPECTION PROCEDURE HINT: Start the inspection from step 1 in case of using the TOYOTA hand–held tester and start from step 2 in case of not using the TOYOTA hand–held tester. 1 Check output value of the each pressure sensor. PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON, and push the TOYOTA hand–held tester main switch ON. (c) Select the DATALIST mode on the TOYOTA hand–held tester. CHECK: Check that the brake fluid pressure value of the master cylinder pressure sensor, regulator pressure sensor, front pressure sensor and rear pressure sensor displayed on the TOYOTA hand–held tester is changing when depressing the brake pedal. OK: Brake fluid pressure value must be changing. OK NG 2001 PRIUS (RM778U) Go to step 4. DI–400 DIAGNOSTICS 2 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check each pressure sensor. ON FRR PREG E2 PFR EFR ERR PMC EREG PREPARATION: (a) Install the LSPV gauge to the front caliper bleeder plug portion, and bleed LSPV gauge. SST 09709–29018 (b) Remove the brake ECU with connectors still connected. CHECK: Turn the ignition switch ON and depress the brake pedal, then check the relation between the fluid pressure and voltage of terminals of each pressure sensor shown below with the connector still connected. Pressure sensor name Symbols Master cylinder pressure sensor Regulator pressure sensor F12669 PMC – E2 PREG – EREG Front pressure sensor PFR – EFR Rear pressure sensor PRR – ERR OK: Front brake caliper fluid pressure 0 kPa (0 Kgf/cm2, 0 psi) Voltage 0.37 – 0.63 V 5,883 kPa (60 kgf/cm2, 853 psi) 1.57 – 1.83 V 11,768 kPa (120 kgf/cm2, 1,706 psi) 2.77 – 3.03 V HINT: It should be taken into account that the difference in voltage between terminals is caused by the slightly different pressure applied to each pressure sensor. OK Go to step 4. NG 3 Check for open and short circuit in harness and connector between each pressure sensor and brake ECU (See page IN–41). NG OK Replace brake actuator. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–401 DIAGNOSTICS 4 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check whether or not the brake ECU terminal STP input voltage is changed when the stop light switch is turned on and off. NO YES Check and replace brake ECU. 2001 PRIUS (RM778U) Check the stop light switch circuit (See page BE–2). DI–402 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI0WV–13 DTC C1241/41 IG Power Source Circuit CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area C1241/41 Either of the following 1. 2. or 3. is detected: 1. While a vehicle is driven at a speed of 3 km/h (5 mph), the condition that the voltage of the terminal IG1 in brake ECU is 9 V or less continues for 10 sec. or more. 2. When the solenoid relay is ON, the contact point of the relay becomes OFF for 0.2 sec. or more due to the voltage decrease of the terminal IG1 in brake ECU. 3. When ignition switch is ON, the voltage of terminal IG1 in brake ECU remains in 17 V or more for 1.2 sec. or more.
Battery
Charging system
Power source circuit WIRING DIAGRAM FL Block No. 1 1 1 DC/DC F13 F11 Brake ECU W B–Y Ignition Switch J/C D J14 E B–Y J15 6 B11 IG1 B–G 2 4 W–G B–Y 6 2D 3 2B 8 B11 GND3 W–B 1 2H 2 2I 17 B11 GND4 W–B 1 FL Block No. 2 W–B AM1 MAIN 1 A 5 ECU–IG 2 3 W–B J11 J/C A IG1 Relay 31 B10 GND1 6 B10 GND2 A J1 J/C 8 2K Battery Instrument Panel J/B ID IE W–B F12678 2001 PRIUS (RM778U) DI–403 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS INSPECTION PROCEDURE 1 Check ECU–IG fuse. PREPARATION: Remove the ECU–IG fuse from instrument panel J/B. CHECK: Check continuity of ECU–IG fuse. OK: Continuity Instrument Panel J/B ECU–IG F12428 NG Check for short circuit in all the harness and components connected to ECU–IG fuse (See attached wiring diagram). NG Check and repair the charging system (See page HV–39). OK 2 Check battery positive voltage. OK: Voltage: 10 – 14 V OK 2001 PRIUS (RM778U) DI–404 DIAGNOSTICS 3 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check voltage of the ECU IG power source. In case of using the TOYOTA hand–held tester: PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON, and push the TOYOTA hand–held tester main switch ON. (c) Select the DATALIST mode on the TOYOTA hand–held tester. CHECK: Check the voltage condition output from the ECU displayed on the TOYOTA hand–held tester. OK: ”Normal” is displayed. In case of not using the TOYOTA hand–held tester: ON PREPARATION: IG1 Remove the brake ECU with connectors still connected. CHECK: Turn the ignition switch ON, measure voltage between terminals IG1 and GND of brake ECU connector. OK: Voltage: 10 – 14 V GND F12405 OK Check and replace brake ECU. NG 4 Check continuity between terminal GND of brake ECU connector and body ground. PREPARATION: Disconnect the 2 connectors (B10, B11) from the brake ECU. CHECK: Measure resistance between terminal GND of brake ECU harness side connector and body ground. OK: Resistance: 1 Ω or less LOCK B10 B11 GND F12406 NG Repair or replace harness or connector. OK Check for open circuit in harness and connector between brake ECU and battery (See page IN–41). 2001 PRIUS (RM778U) DI–405 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI7OO–01 DTC C1242/42 IG2 Power Source Circuit CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area C1242/42 When the vehicle is driven at a speed of 3km/h (5 mph) or more, an open condition in IG2 circuit in brake ECU continues for 7 sec. or more.
Battery
Charging system
Power source circuit WIRING DIAGRAM Brake ECU Instrument Panel J/B W–R 1 2G 2 2C Instrument Panel J/B Ignition Switch W–R B–W 6 7 5 2B 12 1 B–W 2G B12 IG2 W–B Engine Room J/B 9 IJ AM2 2 IB W–B B W–B W–B FL Block No. 1 FL Block No. 2 1 1 MAIN B–G F13 F12 1 Battery GND1 GND2 GND3 GND4 A A J1 J/C IE 31 B10 6 B10 8 B11 17 B11 J11 J/C ID F12679 2001 PRIUS (RM778U) DI–406 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS INSPECTION PROCEDURE 1 Check battery positive voltage. OK: Voltage: 10 – 14 V NG Check and repair the charging system (See page HV–39). OK 2 Check voltage of the ECU IG power source. In case of using the TOYOTA hand–held tester: PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON, and push the TOYOTA hand–held tester main switch ON. (c) Select the DATALIST mode on the TOYOTA hand–held tester. CHECK: Check the voltage condition output from the ECU displayed on the TOYOTA hand–held tester. OK: ”Normal” is displayed. In case of not using the TOYOTA hand–held tester: ON PREPARATION: IG2 Remove the brake ECU with connectors still connected. CHECK: Turn the ignition switch ON, measure voltage between terminals IG2 and GND of brake ECU connector. OK: Voltage: 10 – 14 V GND F10935 OK NG 2001 PRIUS (RM778U) Check and replace brake ECU. DI–407 DIAGNOSTICS 3 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check continuity between terminal GND of brake ECU connector and body ground. PREPARATION: Disconnect the 2 connectors (B10, B11) from the brake ECU. CHECK: Measure resistance between terminals GND of brake ECU harness side connector and body ground. OK: Resistance: 1 Ω or less LOCK B10 B11 GND F12406 NG Repair or replace harness or connector. OK Check for open circuit in harness and connector between brake ECU and battery (See page IN–41). 2001 PRIUS (RM778U) DI–408 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI1GO–09 DTC C1249/49 Stop Light Switch Circuit CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area C1249/49 When the ignition switch is ON, the condition that the terminal STP in brake ECU is 3 – 12 V continues for 1 sec. or more.
Stop light switch
Stop light switch circuit WIRING DIAGRAM Instrument Panel J/B STOP 9 1 2K 2H W J14 J/C Stop Light Switch R–B G–W 2 1 E E F11 1 FL Block No. 1 J/C DC/DC F13 1 1 C J32 B–G C J33 C J33 R6 Stop Light LH W–B G–W 5 2 W–B 1 2 H15 High Mounted Stop Light FL Block No. 2 W–B MAIN G–W G–W E G–W Brake ECU 1 B11 STP IB1 9 A J31 A J31 J/C C J30 G–W C J30 R7 Stop Light RH W–B W–B Battery BI G–W 5 2 BK F12680 2001 PRIUS (RM778U) DI–409 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS INSPECTION PROCEDURE 1 Check operation of the stop light switch. CHECK: Check that the stop light lights up when brake pedal is depressed and turns off when the brake pedal is released. OK Go to step 3. NG 2 Check stop light circuit (See page BE–2). NG Repair or replace stop light circuit. OK 3 Check voltage between terminal STP of brake ECU and body ground. PREPARATION: Remove the brake ECU with connectors still connected. CHECK: Measure voltage between terminal STP of brake ECU and body ground when brake pedal is depressed. OK: Voltage: 8 – 14 V LOCK STP F12407 OK NG 2001 PRIUS (RM778U) Check and replace brake ECU. DI–410 DIAGNOSTICS 4 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check for open circuit in harness and connector between brake ECU and stop light switch (See page IN–41). NG OK Proceed to next circuit inspection on problem symptoms table (See page DI–365). 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–411 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI298–06 DTC C1251/51 Hydraulic Brake Booster Pump Motor Malfunction CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area C1251/51 Either of the following 1. or 2. is detected: 1. After turning the ignition switch ON, the current of more than 28A flows to the motor for more than 1 sec. 2. After turning the ignition switch ON, less than 7A change in current is detected more than 3 times in a row when the motor is ON. Hydraulic brake booster pump motor WIRING DIAGRAM Y–B B W–L 1K 4 ABS No. 2 2 2 1 3 2 4 2 2 1B 2 B Engine Room J/B F12 1 FL Block No. 1 F13 1 1 2 Hydro Motor Relay No. 1 ABS No. 3 1 1 3 2 4 G–W Engine Room R/B No. 2 2 29 B10 MR1 2 B13 MR2 G Y–G H5 2 FL Block No. 2 H5 5 Hydraulic Brake Booster 3 W–L H6 3 Y–G H5 6 Y H5 H6 1 27 B10 MTT 28 B10 MT+ 18 B10 MT– J1 J/C A W–B A W–B Battery Hydro Motor Relay No. 2 LG–R B–G J7 J/C 3 B13 R2+ 2 2 H6 2 MAIN Y–B L–O 1K 6 2 14 IA2 Brake ECU 7 B11 R1+ W–B A A IE F12681 2001 PRIUS (RM778U) DI–412 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS INSPECTION PROCEDURE 1 Check operation of hydraulic brake booster pump motor. BM2 BM1 GND1 GND2 F12408 PREPARATION: Disconnect the 2 connectors from the hydraulic brake booster. CHECK: Connect battery positive
lead to BM1 or BM2 terminal and battery negative  lead to GND1 or GND2 terminal of the hydraulic brake booster (pump motor) connector. OK: The operation sound of the pump motor should be heard. NG Go to step 4. OK 2 Check hydraulic brake booster resistance. GND1 CHECK: Check resistance between terminals MT+ and MT–, BM1 and MTT, BM2 and MTT, GND1 and MT+, GND2 and MT+ of the hydraulic brake booster connector. OK: 30 – 36 Ω GND2 BM1 MT+ MT– MTT F12409 NG OK 2001 PRIUS (RM778U) Replace the hydraulic brake booster assembly. DI–413 DIAGNOSTICS 3 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check for open circuit in harness and connector between hydraulic brake booster and brake ECU (See page IN–41). NG Repair or replace harness or connector. OK Check and replace brake ECU. 4 Check for open or short circuit in harness and connector between hydraulic brake booster pump motor and hydraulic brake booster (See page IN–41). NG Replace wire harness. OK 5 Check hydraulic brake booster pump motor (See page BR–48). NG OK Replace hydraulic brake booster. 2001 PRIUS (RM778U) Replace hydraulic brake booster pump motor. DI–414 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI6AB–02 DTC C1252/52 Hydraulic Brake Booster Pump Motor ON Time Abnormally Long CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area C1252/52 After turning the ignition switch ON, when the power is supplied to the pump motor for more than 5 minutes.
Hydraulic brake booster pump motor
Hydraulic brake booster pump motor circuit
Pressure switch (PH or PL) WIRING DIAGRAM Y–B B W–L 1K 4 ABS No. 2 2 2 1 3 2 4 2 2 1B 2 B Engine Room J/B F12 1 FL Block No. 1 F13 1 1 2 Hydro Motor Relay No. 1 ABS No. 3 1 1 3 2 4 Engine Room R/B No. 2 2 29 B10 MR1 2 B13 MR2 Y–G H5 2 FL Block No. 2 H5 5 Hydraulic Brake Booster 3 W–L H6 3 Y–G H5 6 Y H5 H6 1 27 B10 MTT 28 B10 MT+ 18 B10 MT– J1 J/C A W–B A W–B Battery Hydro Motor Relay No. 2 G B–G J7 J/C 3 B13 R2+ LG–R G–W Brake ECU 7 B11 R1+ 2 2 H6 2 MAIN Y–B L–O 1K 6 2 14 IA2 W–B A A IE F12681 2001 PRIUS (RM778U) DI–415 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS INSPECTION PROCEDURE 1 Check operation of hydraulic brake booster pump motor. BM2 BM1 GND1 GND2 F12408 PREPARATION: Disconnect the 2 connectors from the hydraulic brake booster. CHECK: Connect battery positive
lead to BM1 or BM2 terminal and battery negative  lead to GND1 or GND2 terminal of the hydraulic brake booster (pump motor) connector. OK: The operation sound of the pump motor should be heard. NG Go to step 9. OK 2 Check for short circuit in harness and connector between BM1 or BM2 of hydraulic brake booster and hydro motor relay (See page IN–41). NG Repair or replace harness or connector. OK 3 Check for short circuit in harness and connector between MTT of hydraulic brake booster and brake ECU (See page IN–41). NG OK 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–416 DIAGNOSTICS 4 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check pressure switch (PH). In case of using the TOYOTA hand–held tester: PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON, and push the TOYOTA hand–held tester main switch ON. (c) Select the DATALIST mode on the TOYOTA hand–held tester. CHECK: Depress the brake pedal more than 40 times with the ignition switch OFF then turn the ignition switch ON and check the pressure switch (PH) condition. HINT: When a pressure in power supply system is released, reaction force becomes heavy and stroke becomes shorter. OK: ”OFF” turns to ”ON”. HINT: OFF: Low pressure ON: High pressure In case of not using the TOYOTA hand–held tester: PREPARATION: (a) Disconnect the connector (H8) from the hydraulic brake ON PH LOCK PHG booster. (b) With the ignition switch OFF, depress the brake pedal more than 40 times to decrease the accumulator pressure. H8 F12410 HINT: When a pressure in power supply system is released, reaction force becomes heavy and stroke becomes shorter. CHECK: Measure resistance between terminals PH and PHG of hydraulic brake booster connector. OK: Resistance: 1.0 kΩ PREPARATION: (a) Connect the connector (H8) to the hydraulic brake booster. (b) Disconnect the connector (H8) after ignition switch has been ON and the pump motor has stopped. CHECK: Measure resistance between terminals PH and PHG of hydraulic brake booster connector. OK: Resistance: 0 Ω HINT: After inspection, connect the connector and clear the DTC (See page DI–353). NG 2001 PRIUS (RM778U) Replace hydraulic brake booster assembly. DI–417 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS OK 5 Check pressure switch (PL). In case of using TOYOTA hand–held tester: PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON, and push the TOYOTA hand–held tester main switch ON. (c) Select the DATALIST mode on the TOYOTA hand–held tester. CHECK: Depress the brake pedal more than 40 times with the ignition switch OFF then turn the ignition switch ON and check the pressure switch (PL) condition. HINT: When a pressure in power supply system is released, reaction force becomes heavy and stroke becomes shorter. OK: ”OFF” turns to ”ON”. HINT: OFF: Low pressure ON: High pressure In case of not using TOYOTA hand–held tester: PREPARATION: (a) Disconnect the connector (H9) from the hydraulic brake PL PLG ON LOCK booster. (b) With the ignition switch OFF, depress the brake pedal more than 40 times to decrease the accumulator pressure. HINT: H9 When a pressure in power supply system is released, reaction F12411 force becomes heavy and stroke becomes shorter. CHECK: Measure resistance between terminals PL and PLG of hydraulic brake booster connector. OK: Resistance: 5.7 kΩ PREPARATION: (a) Connect the connector (H9) to the hydraulic brake booster. (b) Disconnect the connector (H9) after ignition switch has been ON and the pump motor has stopped. CHECK: Measure resistance between terminals PL and PLG of hydraulic brake booster connector. OK: Resistance: 1.0 kΩ 2001 PRIUS (RM778U) DI–418 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS HINT: After inspection, connect the connector and clear the DTC (See page DI–353). NG Replace hydraulic brake booster assembly. OK 6 Check for short circuit in harness and connector between pressure switch and brake ECU (See page IN–41). NG OK 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–419 DIAGNOSTICS 7 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check hydro motor relay No. 1 and No. 2. 2 1 4 3 PREPARATION: Remove the hydro motor relay No. 1 and No. 2 from the engine room R/B No. 2. CHECK: Check continuity between each pair of terminal of motor relay. OK: Open 1 2 Terminals 3 and 4 Continuity (Reference value ∗) Terminals 1 and 2 Open * Reference Continuity value: Hydro motor relay No. 1 62 Ω Hydro motor relay No. 2 54 Ω 4 3 Continuity 1 2 (–) 4 CHECK: (a) Apply battery positive voltage between terminals 3 and 4. (b) Check continuity between terminals. OK: 3 Terminals 1 and 2 (+) Continuity F00044 NG Replace hydro motor relay. OK 8 Check for short circuit in harness and connector between hydro motor relay No. 1, No. 2 and brake ECU (See page IN–41). NG OK Check and replace brake ECU. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–420 DIAGNOSTICS 9 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check for open or short circuit in harness and connector between hydraulic brake booster pump motor and hydraulic brake booster (See page IN–41). NG Replace wire harness. OK 10 Check hydraulic brake booster pump motor (See page BR–48). NG OK Replace hydraulic brake booster. 2001 PRIUS (RM778U) Replace hydraulic brake booster pump motor. DI–421 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI29A–13 DTC C1253/53 Hydro Motor Relay Circuit CIRCUIT DESCRIPTION The hydro motor relay supplies power to the hydraulic brake booster pump motor. While the ABS & EBD & RBS are activated, the ECU switches the motor relay ON and operates the hydraulic brake booster pump motor. DTC No. C1253/53 DTC Detecting Condition When any of the following 1. through 4. is detected: 1. After turning the ignition switch ON, open in the relay coil is detected for more than 1 sec. 2. When the pressure switch does not control motor driving, the status that the motor relay is always ON continues for more than 1 sec. due to short circuit. 3. When the pressure switch (PH) detects the low pressure or while the pump motor operates to increase the pressure, the status that the motor relay does not turn ON continues for more than 0.2 sec. 4. When pressure switch does not control motor driving, the status that the motor relay is always ON due to the welded contact continues for more than 2 sec. 2001 PRIUS (RM778U) Trouble Area
Hydro motor relay
Hydro motor relay circuit DI–422 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS WIRING DIAGRAM Brake ECU B Y–B W–L 1K 4 ABS No. 2 2 2 1 3 2 4 2 2 1B 2 B Engine Room J/B F12 1 FL Block No. 1 F13 1 1 2 Hydro Motor Relay No. 1 ABS No. 3 1 1 3 2 4 Engine Room R/B No. 2 2 29 B10 MR1 2 B13 MR2 Y–G H5 2 FL Block No. 2 H5 5 Hydraulic Brake Booster 3 W–L H6 3 Y–G H5 6 Y H5 H6 1 27 B10 MTT 28 B10 MT+ 18 B10 MT– J1 J/C A W–B A W–B Battery Hydro Motor Relay No. 2 G B–G J7 J/C 3 B13 R2+ LG–R G–W 7 B11 R1+ 2 2 H6 2 MAIN Y–B L–O 1K 6 2 14 IA2 W–B A A IE F12681 2001 PRIUS (RM778U) DI–423 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS INSPECTION PROCEDURE HINT: Start the inspection from step 1, in case of using the TOYOTA hand–held tester and start from step 3, in case of not using TOYOTA hand–held tester. 1 Check hydro motor relay operation. PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON, and push the TOYOTA hand–held tester main switch ON. (c) Select the ACTIVE TEST mode on the TOYOTA hand–held tester. CHECK: Check the operation sound of the hydro motor relays individually when operating it with the TOYOTA hand– held tester. OK: The operation sound of the hydro motor relay should be heard. NG Go to step 3. OK 2 Check for short circuit in harness and connector between MTT of hydraulic brake booster and brake ECU (See page IN–41). NG OK Check and replace brake ECU. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–424 DIAGNOSTICS 3 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check voltage between terminal 1 of engine room R/B No. 2 (for hydro motor relays) and body ground. PREPARATION: Remove the hydro motor relay No. 1 and No. 2 from the engine room R/B No. 2. CHECK: Measure voltage between terminal 1 of engine room R/B No. 2 (for hydro motor relays) and body ground. OK: Voltage: 10 – 14 V LOCK 1 1 (+) (–) Engine Room R/B No. 2 F12663 NG Check and repair harness or connector. OK 4 Check hydro motor relay. 2 1 4 3 CHECK: Check continuity between each pair of terminal of motor relay. OK: Open * 1 2 Continuity 4 Terminals 3 and 4 Continuity (Reference value ∗) Terminals 1 and 2 Open Reference value: Hydro motor relay No. 1 62 Ω Hydro motor relay No. 2 54 Ω CHECK: (a) Apply battery positive voltage between terminals 3 and 4. (b) Check continuity between terminals. OK: 3 Continuity 1 Terminals 1 and 2 2 (–) 4 3 (+) F00044 OK 2001 PRIUS (RM778U) NG Replace hydro motor relay. Continuity DI–425 DIAGNOSTICS 5 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check continuity between each terminal 2 of engine room R/B No. 2 (for hydro motor relay) and terminal MTT of brake ECU. Engine Room R/B No. 2 Motor Relay Relay No. 1 2 2 BM1 Relay No. 2 BM2 MTT CHECK: (a) Check continuity betwee terminal 2 of engine room R/B No. 2 (for hydro motor relay No. 1) and terminal MTT of brake ECU. (b) Check continuity between terminal 2 of engine room R/B No. 2 (for hydro motor relay No. 2) and terminal MTT of brake ECU. OK: Continuity HINT: There is resistance of 33 ± 3 Ω between terminals BM1or BM2 and MTT of the hydraulic brake booster. Brake ECU MTT F12412 NG Repair or replace harness, connector or hydraulic brake booster. OK 6 Check for open and short circuit in harness and connector between hydro motor relay No. 1 and No. 2 and brake ECU (See page IN–41). NG OK Check and replace brake ECU. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–426 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI6AC–02 DTC C1254/54 Pressure Switch Circuit CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area C1254/54 Either of the following 1. or 2. is detected: 1. After turning the ignition switch ON, short or open circuit in pressure switch (PL) continued for more than 1 sec. 2. After turning the ignition switch ON open in pressure switch (PH) continued for more than 1 sec.
Pressure switch (PH or PL)
Pressure switch circuit WIRING DIAGRAM Hydraulic Brake Booster High Pressure Switch PH PHG 1 H5 4 H5 Brake ECU 11 GR B10 PH W–B 9 Y–R Low Pressure Switch PL PLG 5 H6 4 H6 B13 PL J7 J/C W–B J1 J/C W–B W–B A A A IE F12682 2001 PRIUS (RM778U) DI–427 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS INSPECTION PROCEDURE 1 Check pressure switch (PL) resistance. PL LOCK PLG H9 F12668 PREPARATION: (a) Disconnect the connector (H9) from the hydraulic brake booster. (b) With ignition switch OFF, depress the brake pedal more than 40 times to decrease the accumulator pressure. HINT: When a pressure in power supply system is released, reaction force becomes heavy and stroke becomes shorter. CHECK: Measure resistance between terminals PL and PLG of hydraulic brake booster connector. OK: Resistance: 5.1 – 6.3 kΩ HINT: After inspection, connect the connector and clear the DTC (See page DI–353). NG OK 2001 PRIUS (RM778U) Replace hydraulic brake booster assembly. DI–428 DIAGNOSTICS 2 LOCK – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check pressure switch (PH) resistance. PH PHG H8 F12413 PREPARATION: (a) Disconnect the connector (H8) from the hydraulic brake booster. (b) With ignition switch OFF, depress the brake pedal more than 40 times to decrease the accumulator pressure. HINT: When a pressure in power supply system is released, reaction force becomes heavy and stroke becomes shorter. CHECK: Measure resistance between terminals PH and PHG of hydraulic brake booster connector. OK: Resistance: 0.9 – 1.1 kΩ HINT: After inspection, connect the connector and clear the DTC (See page DI–353). NG Replace hydraulic brake booster assembly. OK 3 Check for open and short circuit in harness and connector between each pressure switch and brake ECU (See page IN–41). NG OK Check and replace brake ECU. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–429 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI6AD–02 DTC C1256/56 Accumulator Low Pressure Malfunction CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition C1256/56 Either of the following 1. through 5. is detected: 1. With the vehicle running, when the pressure switch (PL) detects high pressure, although ABS, EBD or RBS does not control, the pressure switch (PL) detects low pressure for more than 1.4 sec. 2. With the vehicle running, when the pressure switch (PL) detects high pressure, although ABS, EBD or RBS controls, the pressure switch (PL) detects low pressure for more than 0.2 sec. 3. After the ignition switch is turned ON, the pressure switch (PL) detects low pressure for more than 60 sec. 4. After the ignition switch is ON, PL (Low pressure switch) turns ON while PH (High pressure switch) is stuck to ON, or PL cannot turn OFF for 1.4 sec. or more when running the vehicle without ABS, EBD or RBS control. 5. After the ignition switch is ON, PL turns ON while PH is stuck to ON, or PL cannot turn OFF for 0.2 sec. or more when running the vehicle under ABS, EBD or RBS control. 2001 PRIUS (RM778U) Trouble Area
Accumulator
Pressure switch (PH or PL)
Hydraulic brake booster pump motor DI–430 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS WIRING DIAGRAM Hydraulic Brake Booster High Pressure Switch PH PHG 1 H5 4 H5 Brake ECU 11 GR B10 PH W–B 9 Y–R Low Pressure Switch PL PLG 5 H6 4 H6 B13 PL J7 J/C W–B J1 J/C W–B W–B A A A IE F12682 INSPECTION PROCEDURE 1 Check accumulator operation. PREPARATION: (a) Turn the ignition switch OFF, and depress the brake pedal 40 times or more. HINT: When a pressure in power supply system is released, reaction force becomes heavy and stroke becomes shorter. (b) Install the LSPV gauge (SST) to rear wheel cylinder and bleed air. SST 09709–29018 CHECK: Depress the brake pedal with force of more than 343 N (35 kgf, 77 lbf) and turn the ignition switch ON, then check the rear wheel cylinder pressure when an increase of pressure changes from acutely to mildly. OK: 5,099 – 8,924 kPa (52 – 91 kgf/cm2, 740 – 1,294 psi) at 20°C (68°F) HINT: If the value is not within the standard, cool the engine room and check it again. NG OK 2001 PRIUS (RM778U) Replace accumulator. DI–431 DIAGNOSTICS 2 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check operation of hydraulic brake booster pump motor. BM2 BM1 GND1 GND1 F12408 PREPARATION: Disconnect the 2 connectors from the hydraulic brake booster. CHECK: Connect battery positive
lead to BM1 or BM2 terminal and battery negative  lead to GND1 or GND2 terminal of the hydraulic brake booster (pump motor) connector. OK: The operation sound of the pump motor should be heard. NG OK 2001 PRIUS (RM778U) Go to step 7. DI–432 DIAGNOSTICS 3 LOCK – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check pressure switch (PH) operation. ON PH PHG F12410 LOCK PH PHG F12413 PREPARATION: (a) Turn the ignition switch OFF, and depress the brake pedal 40 times or more. HINT: When a pressure in power supply system is released, reaction force becomes heavy and stroke becomes shorter. (b) Install the LSPV gauge (SST) to the rear wheel cylinder and bleed air. SST 09709–29018 CHECK: While checking the voltage between terminals PH and PHG of hydraulic brake booster, depress the brake pedal with force of more than 343 N (35 kgf, 77 lbf) and turn the ignition switch ON, then check the rear wheel cylinder pressure when voltage changes from 6 V to 0 V. OK: 12,553 – 20,104 kpa (128 – 205 kgf·cm2, 1,820 – 2,916 psi) CHECK: While checking the resistance between terminals PH and PHG, depress the brake pedal changing the force in the range of 197 N (20 kgf, 44 lbf) to 343 N (35 kgf, 77 lbf) and check the rear wheel cylinder pressure when resistance changes from 0 kΩ to 1 kΩ between PH and PHG. OK: 11,964 – 18,240 kpa (122 – 186 kgf·cm2, 1,735 – 2,645 psi) HINT: After inspection, connect the connector, fill brake reservoir with brake fluid and clear the DTC (See page DI–353). OK NG 2001 PRIUS (RM778U) Go to step 5. DI–433 DIAGNOSTICS 4 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check for open circuit in harness and connector between pressure switch (PH) and brake ECU (See page IN–41). NG Repair or replace harness or connector. OK Replace hydraulic brake booster assembly. 5 LOCK Check pressure switch (PL) operation. ON PL PLG F12411 PREPARATION: (a) Turn the motor switch OFF, and depress the brake pedal 40 times or more. HINT: When a pressure in power supply system is released, reaction force becomes heavy and stroke becomes shorter. (b) Install the LSPV gauge (SST) to the rear wheel cylinder and bleed air. SST 09709 –29018 CHECK: While checking the resistance between terminals PL and PLG of hydraulic brake booster, depress the brake pedal with force of more than 343 N (35 kgf, 77 lbf) and turn the ignition switch ON, then check the rear wheel cylinder pressure when the resistance changes from 5.7 kΩ to 1.0 kΩ. OK: 9,022 – 15,102 kpa (92 – 154 kgf·cm2, 1,308 – 2,190 psi) CHECK: While checking the resistance between terminals PL and PLG of hydraulic brake booster, depress the brake pedal changing the force in the range of 197 N (20 kgf, 44 lbf) to 343 N (35 kgf, 77 lbf) and check the rear wheel cylinder pressure when resistance changes from 1.0 kΩ to 5.7 kΩ. OK: 8,532 – 13,337 kpa (87 – 136 kgf·cm2, 1,237 – 1,934 psi) HINT: After inspection, connect the connector, fill brake reservoir with brake fluid and clear the DTC (See page DI–353). NG OK 2001 PRIUS (RM778U) Replace hydraulic brake booster assembly. DI–434 DIAGNOSTICS 6 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check pressure switch (PH) and pressure switch (PL). CHECK: Compare the pressure value of the rear wheel cylinder measured in check pressure switch (PL) operation with the one measured in check pressure switch (PH) operation. OK:
Pressure when the voltage between PH and PHG becomes 6 to 0 V > pressure when the resistance between PL and PLG becomes 5.7 kΩ to 1.0 kΩ.
Pressure when the resistance between PH and PHG becomes 0 kΩ to 1 kΩ > pressure when the resistance between PL and PLG becomes 1.0 kΩ to 5.7 kΩ. NG Replace hydraulic brake booster assembly. OK Check and replace brake ECU. 7 Check for open or short circuit in harness and connector between hydraulic brake booster pump motor and hydraulic brake booster (See page IN–41). NG Replace wire harness. OK 8 Check hydraulic brake booster pump motor (See page BR–48). NG OK Replace hydraulic brake booster. 2001 PRIUS (RM778U) Replace hydraulic brake booster pump motor. DI–435 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI29D–07 DTC C1257/57 Power Supply Drive Circuit CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition C1257/57 Trouble Area After turning the ignition switch ON, open or short circuit in circuit of power supply drive system inside ECU continues for more than 1.5 sec.
Battery
Power source circuit WIRING DIAGRAM FL Block No. 1 1 1 DC/DC F13 F11 Brake ECU W B–Y Ignition Switch J/C D J14 E B–Y J15 6 B11 IG1 B–G 2 4 W–G B–Y 6 2D 3 2B 8 B11 GND3 W–B 1 2H 2 2I 17 B11 GND4 W–B 1 FL Block No. 2 MAIN W–B AM1 1 2 A 5 3 ECU–IG IG1 Relay W–B J11 J/C A 31 B10 GND1 6 B10 GND2 A J1 J/C 8 2K Battery Instrument Panel J/B ID IE W–B F12678 2001 PRIUS (RM778U) DI–436 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS INSPECTION PROCEDURE 1 Check ECU–IG fuse. PREPARATION: Remove the ECU–IG fuse from instrument panel J/B. CHECK: Check continuity of ECU–IG fuse. OK: Continuity Instrument Panel J/B ECU–IG F12428 NG Check for short circuit in all the harness and components connected to ECU–IG fuse (See attached wiring diagram). NG Check and repair the charging system (See page HV–39). OK 2 Check battery positive voltage. OK: Voltage: 10 – 14 V OK 2001 PRIUS (RM778U) DI–437 DIAGNOSTICS 3 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check voltage of the ECU IG power source. In case of using the TOYOTA hand–held tester: PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON, and push the TOYOTA hand–held tester main switch ON. (c) Select the DATALIST mode on the TOYOTA hand–held tester. CHECK: Check the voltage condition output from the ECU displayed on the TOYOTA hand–held tester. OK: ”Normal” is displayed. In case of not using the TOYOTA hand–held tester: ON PREPARATION: IG1 Remove the brake ECU with connectors still connected. CHECK: Turn the ignition switch ON, measure voltage between terminals IG1 and GND of brake ECU connector. OK: Voltage: 10 – 14 V GND F12405 OK Check and replace brake ECU. NG 4 Check continuity between terminal GND of brake ECU connector and body ground. PREPARATION: Disconnect the 2 connectors (B10, B11) from the brake ECU. CHECK: Measure resistance between terminal GND of brake ECU harness side connector and body ground. OK: Resistance: 1 Ω or less LOCK B10 B11 GND F12406 NG Repair or replace harness or connector. OK Check for open circuit in harness and connector between brake ECU and battery (See page IN–41). 2001 PRIUS (RM778U) DI–439 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI7OQ–01 DTC Always ON Malfunction in ECU CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Always ON Trouble Area
Battery
Charging system
Power source circuit
Brake ECU Either of the following 1. or 2. is detected: 1. ECU connectors are disconnected from ECU 2. There is a malfunction in ECU internal circuit HINT: There is a case that TOYOTA hand–held tester cannot be used when ECU is abnormal. WIRING DIAGRAM FL Block No. 1 1 1 DC/DC F13 F11 Brake ECU W B–Y Ignition Switch J/C D J14 E B–Y J15 6 B11 IG1 B–G 2 4 W–G B–Y 6 2D 3 2B 8 B11 GND3 W–B 1 2H 2 2I 17 B11 GND4 W–B 1 FL Block No. 2 MAIN W–B AM1 1 2 A 5 3 ECU–IG IG1 Relay W–B J11 J/C A 31 B10 GND1 6 B10 GND2 A J1 J/C 8 2K Battery Instrument Panel J/B ID IE W–B F12678 2001 PRIUS (RM778U) DI–440 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS INSPECTION PROCEDURE 1 Check that brake ECU connectors are securely connected to brake ECU. NO Connect connectors to brake ECU. YES Repair circuit indicated by output code. YES Check ABS solenoid relay. Check for short circuit in harness and connector between ABS solenoid relay and DLC3 (See page IN–41). YES 2 Is DTC output? Check DTC on page DI–353. NO 3 Is normal code displayed? NO 4 Does ABS warning light go off? YES NO 2001 PRIUS (RM778U) Check for open or short circuit in harness and connector between ECU–IG fuse and brake ECU (See page IN–41). DI–441 DIAGNOSTICS 5 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check battery positive voltage. CHECK: Check the battery positive voltage. OK: Voltage: 10 – 14 V NG Check and repair charging system (See page HV–39). OK 6 Check operation of the ABS warning light. In case of using the TOYOTA hand–held tester: PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON, and push the TOYOTA hand–held tester main switch ON. (c) Select the ACTIVE TEST mode on the TOYOTA hand–held tester. CHECK: Check that ”ON” and ”OFF” of the ABS warning light can be shown on the combination meter by the TOYOTA hand–held tester. In case of not using the TOYOTA hand–held tester: (a) Disconnect the connector (B11) from the brake ECU. (b) Using service wire, connect terminal WA of brake ECU ON harness side connector and body ground. WA (c) Turn the ignition switch ON. B11 OK: ABS warning light goes off. F12444 OK Check and replace brake ECU. NG Check for short circuit in harness and connector between combination meter and brake ECU, combination meter and DLC3 (See page IN–41). Check ABS solenoid relay circuit (See page DI–376). 2001 PRIUS (RM778U) DI–442 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI29F–14 ABS Warning Light Circuit CIRCUIT DESCRIPTION If the ECU detects trouble, it lights the ABS warning light while at the same time prohibiting ABS control. At this time, the ECU records a DTC in memory. Connect terminals Tc and CG of the DLC3 to make the ABS warning light blink and output the DTC. WIRING DIAGRAM B–G Brake ECU FL Block No. 1 1 DC/DC 1 F13 F11 L W B–W 18 B11 WA IP1 2 Ignition Switch L 2 4 C10 22 C10 10 B–Y W–G 2D 6 2B 3 2H 1 2A 5 ABS AM1 1 FL Block No. 2 GAUGE 1 5 2 3 MAIN 7 2A 8 2K C10 14 Commbination Mater 6 2B J11 J/C W–B Battery L Instrument Panel J/B BR A ID IH F12683 2001 PRIUS (RM778U) DI–443 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS INSPECTION PROCEDURE HINT: Troubleshoot in accordance with the chart below for each trouble symptom. ABS warning light does not light up *1 ABS warning light remains on *2 *1: Start the inspection from step 1 in case of using the TOYOTA hand–held tester and start from step 2 in case of not using TOYOTA hand–held tester. *2: After inspection with step 4, start the inspection from step 5 in case of using the TOYOTA hand–held tester and start from step 6 in case of not using TOYOTA hand–held tester. 1 Check operation of the brake warning light. PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON, and push the TOYOTA hand–held tester main switch ON. (c) Select the ACTIVE TEST mode on the TOYOTA hand–held tester. CHECK: Check that ”ON” and ”OFF” of the ABS warning light can be shown on the combination meter on the TOYOTA hand–held tester. OK Check and replace brake ECU. NG 2 Check ABS warning light. See combination meter troubleshooting on page BE–2. NG OK 2001 PRIUS (RM778U) Repair bulb or combination meter assembly. DI–444 DIAGNOSTICS 3 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check ABS solenoid relay. 3 2 1 6 5 4 PREPARATION: Remove the ABS solenoid relay from engine room R/B No. 3. CHECK: Check continuity between each terminal of ABS solenoid relay. OK: Open 3 2 1 Terminals 4 and 6 Continuity (Reference value 80 Ω) Terminals 2 and 3 Continuity Terminals 1 and 3 Open Continuity Continuity CHECK: (a) Apply battery positive voltage between terminals 4 and 6. (b) Check continuity between each terminal of ABS solenoid relay. OK: 65 4 Continuity 3 2 1 Terminals 2 and 3 Open Terminals 1 and 3 Continuity Open (–) 6 5 4 CHECK: Connect the
test lead to terminal 5 and the  lead to terminal 3. Check continuity between the terminals. OK: Continuity If there is no continuity, connect the  test lead to terminal 5 and the
lead to terminal 3. Recheck continuity between terminals. (+) Continuity (–) 3 2 1 (+) 65 4 F00043 NG Replace ABS solenoid relay. OK Repair or replace and check for open circuit in harness and connector between DLC3 and ABS solenoid relay and body ground (See page IN–41). 2001 PRIUS (RM778U) DI–445 DIAGNOSTICS 4 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check that the brake ECU connectors are securely connected to the brake ECU. NO Connect the connector to the brake ECU. YES 5 Check operation of the ABS warning light (See step 1). OK Check and replace brake ECU. YES Repair circuit indicated by the output code. NG 6 Is DTC output? Check DTC on page DI–353. NO 7 Check ABS solenoid relay (See step 3). NG Replace ABS solenoid relay. OK Check for short circuit in harness and connector between DLC3 and ABS solenoid relay (See page IN–41). 2001 PRIUS (RM778U) DI–446 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI29G–14 BRAKE Warning Light Circuit CIRCUIT DESCRIPTION The BRAKE warning light lights up when the brake fluid is insufficient, the parking brake is applied or the EBD is defective. The BRAKE warning light also lights up when DTC No. C1213/63 or C1259/59 is detected, however, the EBD is not inhibited in this case. WIRING DIAGRAM Parking Brake Switch Brake ECU J12 J/C R–Y R–Y 1 E E 18 IA2 13 B12 PKB R–Y Instrument Panel J/B FL Block No. 2 MAIN FL Block No. 1 1 1 DC/DC F13 F11 B–G 1 Body ECU 15 Ignition Switch W–G 2 GR–B W B–Y 4 5 2 R–Y 2K B11 BRL 4 B8 16 B8 GR Multiplex Communication Circuit L Instrument Panel J/B C10 22 C11 2 C11 3 LG–R 6 2D 3 2B 1 2H 5 2A AM1 1 Brake Fluid Level Warning Switch GAUGE 5 2 Brake IG1 Relay 2 7 B12 LBL 3 Commbination Meter 7 2A L A 14 C10 BR A A A W–B Battery W–B J7 J/C W–B 6 2B 8 2K 1 ID IH J1 J/C IE J11 J/C F12684 2001 PRIUS (RM778U) DI–447 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS INSPECTION PROCEDURE HINT: Start the inspection from step 1 in case of using the TOYOTA hand–held tester and start from step 2 in case of not using the TOYOTA hand–held tester. 1 Check operation of the BRAKE warning light. PREPARATION: (a) Release the parking brake pedal. (b) Connect the TOYOTA hand–held tester to the DLC3. (c) Turn the ignition switch ON, and push the TOYOTA hand–held tester main switch ON. (d) Select the ACTIVE TEST mode on the TOYOTA hand–held tester. CHECK: Check that ”ON” and ”OFF” of BRAKE warning light can be shown on the combination meter by the TOYOTA hand–held tester. OK Check and replace brake ECU. NG 2 Check parking brake switch circuit (See page BE–2). NG Repair or replace parking brake switch circuit. OK 3 Check brake fluid level warning switch circuit (See page BE–2). NG Repair or replace brake fluid level warning switch circuit. Yes Repair circuit indicated by the output code. OK 4 Is DTC output for ABS ? No 2001 PRIUS (RM778U) DI–448 DIAGNOSTICS 5 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check BRAKE warning light. See combination meter troubleshooting on page BE–2. NG Repair or replace combination meter. OK 6 Check multiplex communication system (See page DI–752). NG OK Check and replace brake ECU. 2001 PRIUS (RM778U) Repair or replace multiplex communication circuit. DI–449 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI29H–07 Brake Warning Buzzer Circuit CIRCUIT DESCRIPTION The brake warning buzzer sounds while the accumulator pressure is abnormally low. WIRING DIAGRAM FL Block No. 2 MAIN B–G 1 Brake ECU FL Block No. 1 1 1 DC/DC F11 F13 13 IA2 G Ignition Switch 4 BUZZER 1 D J14 B–Y B–Y 3 2B 1 2H J/C 8 B11 GND3 W–B 17 B11 GND4 W–B ECU–IG 5 IG1 Relay 2 E J15 2 2I AM1 1 2 B–Y W–G 6 2D 20 B12 BZ Brake Warning Buzzer W 2 G W–B 3 W–B 31 B10 GND1 6 B10 GND2 8 2K Instrument Panel J/B J11 J/C W–B Battery A A A ID J1 J/C IE F12685 2001 PRIUS (RM778U) DI–450 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS INSPECTION PROCEDURE HINT: Start the inspection from step 1 in case of using the TOYOTA hand–held tester and start from step 2 in case of not using the TOYOTA hand–held tester. 1 Check operation of the brake warning buzzer. PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON, and push the TOYOTA hand–held tester main switch ON. (c) Select the ACTIVE TEST mode on the TOYOTA hand–held tester. CHECK: Check that brake warning buzzer sounds ”ON” and ”OFF” with the TOYOTA hand–held tester. OK Check and replace brake ECU. NG 2 Check brake warning buzzer. PREPARATION: Disconnect the brake warning buzzer connector. CHECK: Apply battery positive voltage to the terminals 1 and 2 of BRAKE warning buzzer connector, check that the brake warning buzzer sounds. 1 2 (+) (–) F02192 NG OK 2001 PRIUS (RM778U) Replace brake warning buzzer. DI–451 DIAGNOSTICS 3 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check for open and short circuit in harness and connector between brake ECU and brake warning buzzer (See page IN–41). NG OK Check and replace brake ECU. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–452 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI29I–13 Tc Terminal Circuit CIRCUIT DESCRIPTION Connecting terminals Tc and CG of the DLC3 causes the ECU to display the DTC by flashing the ABS warning light. WIRING DIAGRAM DLC3 J26 J/C Tc E J24 J/C CG W–B A 4 2 ID1 P–B P–B E 13 P–B A 8 2D C 8 2K 3 B11 Tc P–B C J11 J/C Instrument Panel J/B W–B Brake ECU J16 J/C W–B A ID F12686 INSPECTION PROCEDURE 1 Check voltage between terminals Tc and CG of DLC3. PREPARATION: Turn the ignition switch ON. CHECK: Measure voltage between terminal Tc and CG of DLC3. OK: Voltage: 10 – 14 V ON DLC3 (+) (–) Tc CG F09678 OK NG 2001 PRIUS (RM778U) If ABS warning light does not blink even after Tc and CG are connected, the ECU may be defective. DI–453 DIAGNOSTICS 2 – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS Check for open and short circuit in harness and connector between brake ECU and DLC3, DLC3 and body ground (See page IN–41). NG OK Check and replace brake ECU. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–454 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS DI29J–12 Ts Terminal Circuit CIRCUIT DESCRIPTION The sensor check circuit detects abnormalities in the speed sensor signal which cannot be detected by the DTC check. Connecting terminals Ts and CG of the DLC3 starts the check. WIRING DIAGRAM DLC3 Ts 3 ID1 GR–G 14 J24 J/C CG W–B A 4 A B B 8 2D 8 2K 4 B11 Ts GR–G GR–G J11 J/C Instrument Panel J/B W–B Brake ECU J16 J/C W–B A ID C 2001 PRIUS (RM778U) F12687 DI–455 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH EBD & RBS INSPECTION PROCEDURE 1 Check voltage between terminals Ts and CG of DLC3. CHECK: (a) Turn the ignition switch ON. (b) Measure voltage between terminals Ts and CG of DLC3. OK: Voltage: 10 – 14 V ON DLC3 (+) (–) Ts CG F09679 OK If ABS warning light does not blink even after Ts and CG are connected, the ECU may be defective. NG 2 Check for open and short circuit in harness and connector between brake ECU and DLC3, DLC3 and body ground (See page IN–41). NG OK Check and replace brake ECU. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–459 DIAGNOSTICS – ELECTRIC MOTOR POWER STEERING DI7QW–01 PRE–CHECK 1. (a) DIAGNOSIS SYSTEM Check the indicator. When the ignition switch is turned ON, check that the PS warning light goes on for 1.5 seconds. HINT:
If the indicator check result is not normal, proceed to troubleshooting for the PS warning light circuit (See page DI–486).
When the EMPS system is faulty, the master warning light in the combination meter and the PS warning light in the multiinformation display lights up. (b) In case of not using TOYOTA hand–held tester: Check the DTC. (1) Using SST, connect terminals Tc and CG of the DLC3. SST 09843–18040 F12845 F12874 Tc CG F12846 (2) WL (3) (4) (5) PGND F12873 2001 PRIUS (RM778U) Remove the EMPS ECU with connector still connected. Connect the both terminals of the 1kΩ resistance and LED (Light Emitting Diode) circuit to terminals WL and PGND of the EMPS ECU. Turn the ignition switch ON. Read the DTC from the PS warning light. DI–460 DIAGNOSTICS
0.25 sec. 0.25 sec.
ON OFF Codes 21 and 22 1.5 sec. ELECTRIC MOTOR POWER STEERING HINT: Normal Code 0.5 sec. 0.5 sec. – 2.5 sec. 0.5 sec. 4 sec. If no code appears, inspect the diagnostic circuit and PS warning light circuit (See page DI–491 or DI–486). As an example, the blinking patterns for normal code and codes 21 and 22 are shown on the left. (6) Codes are explained in the DTC chart on page DI–460. (7) After completing the check, disconnect terminals Tc and CG of the DLC3, and turn off the display. If 2 or more malfunctions are indicated at the same time, the lowest numbered DTC will be displayed first. ON OFF Code 21 Code 22 F12870 TOYOTA Hand–held Tester DLC3 F12396 Ts CG F12861 2001 PRIUS (RM778U) (c) In case of using TOYOTA hand–held tester: Check the DTC. (1) Hook up the TOYOTA hand–held tester to the DLC3. (2) Turn the ignition switch ON. (3) Read the DTC by following the prompts on the tester screen. HINT: Please refer to the TOYOTA hand–held tester operator’s manual for further details. (d) In case of not using TOYOTA hand–held tester: Clear the DTC. (1) Using SST, connect terminals Ts and CG of DLC3. SST 09843–18040 (2) Turn the ignition switch ON. (3) ON and OFF the terminal CG of the DLC3 4 times or more within 8 seconds, delete DTC of the EMPS ECU. (4) Check that the PS warning light shows the normal code. (5) Remove the SST from the DLC3. SST 09843–18040 DI–461 DIAGNOSTICS TOYOTA Hand–held Tester – ELECTRIC MOTOR POWER STEERING (e) In case of using TOYOTA hand–held tester: Clear the DTC. (1) Hook up the TOYOTA hand–held tester to the DLC3. (2) Turn the ignition switch ON. (3) Operate the TOYOTA hand–held tester to erase the codes. (See TOYOTA hand–held tester operator’s manual.) 2. (a) INPUT SIGNAL CHECK (TEST MODE) In case of not using TOYOTA hand–held tester: Check the input signal. (1) Turn the ignition switch OFF. (2) Using SST, connect terminals Ts and CG of DLC3. SST 09843–18040 (3) Check the warning light goes off with driving more than 20 km/h (12 mph). DLC3 F12396 Ts Tc CG F12848 HINT: If the warning light goes off during driving, the sensor can be judged to normal. (4) Stop the vehicle. (5) Using SST, connect terminals Tc and CG of DLC3. SST 09843–18040 (6) Read the number of blinks of the PS warning light. HINT:
See the list of DTC shown on the next page.
Even a sensor is normal, it output codes 71 and 72 during test mode. Malfunction Code (Example Code 72) Normal Code 7 ON 2 ON OFF 0.25 sec. OFF 0.5 sec. 0.5 sec. 1.5 sec. 4 sec. 0.25 sec. 0.5 sec. A Cycle 0.5 sec. Repeat F12871 (7) After doing check, disconnect the SST from the terminals Ts and CG, Tc and CG of DLC3, and turn the ignition switch OFF. SST 09843–18040 2001 PRIUS (RM778U) DI–462 DIAGNOSTICS TOYOTA Hand–held Tester (b) DLC3 F12396 – ELECTRIC MOTOR POWER STEERING In case of using TOYOTA hand–held tester: Check the input signal. (1) Hook up the TOYOTA hand–held tester to the DLC3. (2) Check the warning light goes off with driving more than 20 km/h (12 mph). (3) Read the DTC by following the prompts on the tester screen. HINT:


Please refer to the TOYOTA hand–held tester operator’s manual for further details. See the list of DTC shown on the bottom of this page. Even a sensor is normal, it output codes 71 and 72 during test mode. DTC of input signal check function: Code No. (See page) Diagnosis Trouble Area C1515/15 (DI–468) Calibration of torque sensor zero point Not Performed – C1516/16 (DI–469) Calibration of torque sensor zero point Not completed – C1571/71 C1572/72 (DI–474) Speed sensor malfunction (Test mode)
Right rear or left rear speed sensor
Sensor installation
Right rear or left rear speed sensor rotor
Right rear or left rear speed sensor circuit
Brake ECU
EMPS ECU 3. CALIBRATION OF TORQUE SENSOR ZERO POINT HINT: Perform this operation in the following cases.
When removing and installing ”steering wheel”, ”tilt steering column”and ”electric power steering gear”.
When replacing EMPS ECU. (a) Place front wheels and steering wheel facing straight ahead. (b) In case of using TOYOTA hand–held tester: Perform the torque sensor zero point initialization. HINT: If the EMPS ECU is replaced, however, this operation is not necessary. (1) Stop the vehicle. 2001 PRIUS (RM778U) DI–463 DIAGNOSTICS TOYOTA Hand–held Tester – (2) (3) (4) (5) DLC3 F12396 Tc Ts CG F12827 Tc CG F12864 2001 PRIUS (RM778U) ELECTRIC MOTOR POWER STEERING Hook up the TOYOTA hand–held tester to the DLC3. Select the ”TRQ SENS ADJUST” mode on the TOYOTA hand–held tester. Select the ”ZERO POINT INITIALIZE”. Following the screen instructions, perform the torque sensor zero point initialization. HINT: Please refer to the TOYOTA hand–held tester operator’s manual for further details. (c) In case of not using TOYOTA hand–held tester: Perform the torque sensor zero point initialization. HINT: If the EMPS ECU is replaced, however, this operation is not necessary. (1) Stop the vehicle. (2) Using SST, connect terminals Ts and CG of DLC3. SST 09843–18040 (3) Using SST, connect terminals Tc and CG of DLC3. SST 09843–18040 (4) ON and OFF the terminal Tc of DLC3 20 times within 20 sedonds. (5) Check that the DTC C1515/15. (d) In case of using TOYOTA hand–held tester: Perform the torque sensor zero point calibration. HINT: Don’t touch the steering wheel. (1) Select the ”TRQ SENS ADJUST” mode on the TOYOTA hand–held tester. (2) Select the ”ZERO POINT ADJUST”. (3) Following the screen instructions, perform the torque sensor zero point calibration. HINT: Please refer to the TOYOTA hand–held tester operator’s manual for further details. (e) In case of not using TOYOTA hand–held tester: Perform the torque sensor zero point calibration. HINT:
Don’t touch the steering wheel.
Check the DTC except C1515/15 is not output. (1) Stop the vehicle and turn the ignition switch OFF. DI–464 DIAGNOSTICS (2) ELECTRIC MOTOR POWER STEERING Using SST, connect terminals Ts and CG of DLC3 and ignition switch ON. SST 09843–18040 (3) Disconnect the SST. SST 09843–18040 Ts CG F12848 2001 PRIUS (RM778U) – DI–465 DIAGNOSTICS – ELECTRIC MOTOR POWER STEERING DI7QX–01 DIAGNOSTIC TROUBLE CODE CHART HINT:

Using SST 09843–18040, connect terminals Tc and CG of the DLC3. If a malfunction code is displayed during the DTC check, check the circuit listed for the code. For details of each code, turn to the page referred to under the ”See page” for respective ”DTC No.” in the DTC chart. DTC No. (See page) Detection Item Trouble Area C1511/11 (DI–465) C1512/12 (DI–465) T Torque sensor circuit i it malfunction lf ti
Torque sensor
EMPS ECU M t circuit Motor i it malfunction lf ti
Power steering gear assembly with motor
EMPS ECU EMPS ECU malfunction EMPS ECU Speed sensor malfunction
Speed sensor
Brake ECU
EMPS ECU C1551/51 (DI–476) IG power source circuit malfunction
EMPS ECU
Power source circuit
Charging system C1552/52 (DI–479) PIG power source drop voltage malfunction
EMPS ECU
Power source circuit C1553/53 (DI–482) When resetting voltage, vehicle is being driven EMPS ECU C1554/54 (DI–483) EMPS relay circuit malfunction
EMPS relay
EMPS ECU
EMPS relay circuit C1555/55 (DI–473) EMPS ECU malfunction EMPS ECU C1556/56 (DI–486) P/S warning light circuit
Multiinformation display
EMPS ECU C1513/13 (DI–465) C1514/14 (DI–465) C1521/21 (DI–471) C1522/22 (DI–471) C1523/23 (DI–471) C1524/24 (DI–471) C1531/31 (DI–473) C1532/32 (DI–473) C1533/33 (DI–473) C1541/41 (DI–474) C1542/42 (DI–474) C1543/43 (DI–474) 2001 PRIUS (RM778U) DI–466 DIAGNOSTICS – ELECTRIC MOTOR POWER STEERING C1557/57 (DI–488) Memory of overheat prevention control – C1558/58 (DI–488) Memory of voltage drop at motor power supply – C1559/59 (DI–488) Memory of continuous control under high load – Always ON (DI–489) Malfunction in EMPS ECU 2001 PRIUS (RM778U)
Power source circuit
EMPS ECU
PS warning light circuit DI–470 DIAGNOSTICS – ELECTRIC MOTOR POWER STEERING DI7R1–01 CIRCUIT INSPECTION DTC C1511/11–C1514/14 Torque Sensor Circuit Malfunction CIRCUIT DESCRIPTION Steering torque is detected from output current of torque sensor. DTC No. Detection Item Trouble Area C1511/11 C1512/12
Power steering gear assembly with motor
EMPS ECU Torque sensor malfunction C1513/13 C1514/14 Open or short torque sensor circuit WIRING DIAGRAM Steering Shaft Torque Sensor 5 I01 VCC (Shielded) 2 W 1 E3 TRQV 1 R 4 E3 TRQ1 3 G 2 E3 TRQ2 4 B 3 E3 TRQG W–B A J/C A J19 J18 VT1 W–B VT2 J17 J/C A GND EMPS ECU IG W–B F12832 2001 PRIUS (RM778U) DI–471 DIAGNOSTICS – ELECTRIC MOTOR POWER STEERING INSPECTION PROCEDURE 1 Check voltage between terminals TRQV and TRQG of EMPS ECU. ON PREPARATION: Remove the EMPS ECU with connectors still connected. CHECK: Measure the voltage between terminals TRQV and TRQG of EMPS ECU connector. OK: Voltage: 4.5 – 5.5 V TRQV TRQG F12270 NG Check and replace the EMPS ECU. OK 2 Check for open and short circuit in harness and connector between terminals TRQV and TRQG of EMPS ECU connector (See page IN–41). NG Repair and replace harness or connector. OK 3 Check voltage between terminals VT1 and GND, VT2 and GND of torque sensor connector. VT1 VT2 GND F12271 2001 PRIUS (RM778U) PREPARATION: Remove the torque sensor with connectors still connected. CHECK: Measure the voltage between terminals VT1 and GND, VT2 and GND of torque sensor connector. OK: Steering Position VT1 VT2 Center position 2.1 – 2.9 V 2.1 – 2.9 V Right turned 0.15 – 2.9 V 2.1 – 4.85 V Left turned 2.1 – 4.85 V 0.15 – 2.9 V DI–472 DIAGNOSTICS NG – ELECTRIC MOTOR POWER STEERING Check and replace power steering gear assembly with motor (See page SR–17). OK 4 Check for open and short circuit in harness and connector between terminals VT1 of torque sensor connector and TRQ1 of EMPS ECU connector, VT2 of torque sensor connector and TRQ2 of EMPS ECU connector (See page IN–41). NG OK Check and replace EMPS ECU. 2001 PRIUS (RM778U) Repair and replace harness or connector. DI–474 DIAGNOSTICS – ELECTRIC MOTOR POWER STEERING DI7R3–01 DTC C1516/16 Calibration of Torque Sensor Zero Point Not Completed CIRCUIT DESCRIPTION This DTC does not indicated trouble. This is detected when the torque sensor zero point calibration is not completed normally. DTC No. DTC Detecting Condition Trouble Area C1516/16 This is detected when the torque sensor zero point calibration is not completed normally. – INSPECTION PROCEDURE 1 Perform calibration of torque sensor zero point (See page DI–454). 2 Is DTC C1516/16 output? Check DTC on page DI–460. NO No problem. YES Check and replace EMPS ECU. YES 3 Is DTC C1532/32 output? NO 4 Perform calibration of torque sensor zero point again (See page DI–454). 2001 PRIUS (RM778U) DI–475 DIAGNOSTICS 5 – ELECTRIC MOTOR POWER STEERING Is DTC C1516/16 output after attempted 3 times or more? YES NO No problem. 2001 PRIUS (RM778U) Replace the power steering gear assembly with motor. DI–476 DIAGNOSTICS – ELECTRIC MOTOR POWER STEERING DI7R4–01 DTC C1521/21–C1524/24 Motor Circuit Malfunction CIRCUIT DESCRIPTION DTC No. Detection Item Trouble Area C1521/21 C1522/22 C1523/23 Short circuit of motor terminal or abnormal voltage or current in motor circuit.
Power steering gear assembly with motor
EMPS ECU C1524/24 WIRING DIAGRAM EMPS ECU Y 1 E4 M1 B–Y 2 E4 M2 2 DC Motor 1 F12834 INSPECTION PROCEDURE 1 Check voltage between terminals M1 and M2 of EMPS ECU connector. ON PREPARATION:
Remove the EMPS ECU with connectors still connected.
Turn the ignition switch ON. CHECK: Turn the steering wheel to left and right and measure the voltage between terminals M1 and M2 of EMPS ECU connector. OK: Voltage: 9 – 14 V M1 M2 F12819 NG 2001 PRIUS (RM778U) Check and replace the EMPS ECU. DI–477 DIAGNOSTICS – ELECTRIC MOTOR POWER STEERING OK 2 Check for open and short circuit in harness and connector between terminals M1 and M2 of EMPS ECU connector (See page IN–41). NG Repair or replace harness or connector. OK 3 Check continuity between terminal M1 and M2 of motor connector. M2 PREPARATION: Disconnect the connector from the motor. CHECK: Measure the resistance between terminals M1 and M2 of motor connector. OK: Resistance: 0.1 – 1 Ω M1 F12820 NG OK Check and replace the EMPS ECU. 2001 PRIUS (RM778U) Check and replace the power steering gear assembly with motor (See page SR–17). DI–479 DIAGNOSTICS – ELECTRIC MOTOR POWER STEERING DI7R6–01 DTC C1541/41–C1543/43 Speed Sensor Malfunction DTC C1571/71, C1572/72 Speed Sensor Malfunction (Test Mode) CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area C1541/41 C1542/42 Speed S eed sensor malfunction
Speed sensor
Brake ECU
EMPS ECU S Speed d sensor malfunction lf ti (Test (T t mode) d )
Right rear or left rear speed sensor
Sensor installation
Right rear or left rear sspeed eed sensor rotor
Right rear or left rear speed sensor circuit
Brake ECU
EMPS ECU C1543/43 C1571/71 C1572/72 WIRING DIAGRAM BRAKE ECU EMPS ECU (Shielded) 15 B11 W 10 E6 WRL 23 RRO B11 B 4 E6 WRR RLO J17 J/C A W–B A J/C A J18 J19 IG F12836 2001 PRIUS (RM778U) DI–480 DIAGNOSTICS – ELECTRIC MOTOR POWER STEERING INSPECTION PROCEDURE 1 Check continuity between terminals WRR and PGND, WRL and PGND of EMPS ECU connector. ON WRR PGND WRL PGND PREPARATION: Remove the EMPS ECU with connectors still connected. CHECK: Turn the ignition switch ON and measure the resistance between terminals WRR and PGND, WRL and PGND of EMPS ECU connector. OK: Resistance:1M Ω or higher F12822 NG Check and replace the EMPS ECU. OK 2 Check for open and short circuit in harness and connector between terminals WRR of EMPS ECU connector and RRO of brake ECU connector, WRL of EMPS ECU and RLO of brake ECU connector (See page IN–41). NG Repair and replace harness or connector. OK 3 Check the DTC for the ABS with EBD and RBS (See page DI–351). *1 *1: Output NG code 2001 PRIUS (RM778U) Repair ABS with EBD and RBS control system according to the code output. DI–481 DIAGNOSTICS – ELECTRIC MOTOR POWER STEERING DI7R7–01 DTC C1551/51 IG Power Source Circuit Malfunction CIRCUIT DESCRIPTION The EMPS ECU identifies ON or OFF status of ignition switch by this circuit. DTC No. C1551/51 DTC Detecting Condition Trouble Area The abnormal IG voltage value which is not within the specification is input to EMPS ECU.
EMPS ECU
Power source circuit
Charging system WIRING DIAGRAM EMPS ECU D J14 B–Y J/C E J15 5 E6 IG B–Y Instrument Panel J/B 2 2I IG1 Relay ECU–IG 3 1 2H 5 AM1 W–B 8 2K 2 W–G 3 2B F18 FL Block No. 2 MAIN J11 J/C IG S/W 6 B–Y4 2D 1 A W 1 B–G 2 FL Block No. 1 1 F13 DC/DC 1 F11 J17 J/C A W–B ID Battery 2 E5 PGND IG F12837 2001 PRIUS (RM778U) DI–482 DIAGNOSTICS – ELECTRIC MOTOR POWER STEERING INSPECTION PROCEDURE 1 Check ECU–IG fuse. ECU–IG Fuse PREPARATION: Remove the ECU–IG fuse from the instrument panel J/B. CHECK: Check the continuity of the ECU–IG. OK: Continuity Instrument Panel J/B F12823 NG Check for short circuit in all harness and components connected to ECU–IG fuse (See attached wiring diagram). OK 2 Check that the battery positive voltage when IG switch is OFF. OK: Voltage: 9 – 14 V NG OK 2001 PRIUS (RM778U) Charge or replace the battery. DI–483 DIAGNOSTICS 3 – ELECTRIC MOTOR POWER STEERING Check voltage between terminals IG and PGND of EMPS ECU connector. ON PREPARATION: Remove the EMPS ECU with connectors still connected. CHECK: Turn the ignition switch ON and measure the voltage between terminals IG and PGND of EMPS ECU connector. OK: Voltage: 9 – 14 V IG PGND F12824 OK Check and replace the EMPS ECU. NG 4 Check continuity between terminals PGND of EMPS ECU connector and body ground. LOCK CHECK: Measure the resistance between terminals PGND of EMPS ECU connector and body ground. OK: Resistance: 1 Ω or less PGND F12825 NG Repair or replace harness or connector. OK Check for open and short circuit in harness and connector between EMPS ECU and ECU–IG fuse (See page IN–41). 2001 PRIUS (RM778U) DI–484 DIAGNOSTICS – ELECTRIC MOTOR POWER STEERING DI7R8–01 DTC C1552/52 PIG Power Source Circuit CIRCUIT DESCRIPTION When turning ignition switch ON, battery voltage is supplied to terminal PIG of EMPS ECU by EMPS relay operation. DTC No. C1552/52 DTC Detecting Condition Trouble Area The abnormal motor power source voltage value which is not within the specification is input to EMPS ECU.
EMPS ECU
Power source circuit WIRING DIAGRAM Engine Room R/B No. 3 EMPS Relay 3 3 B–R R–G 3 5 1 2 3 3 B 1 IM1 B GR 7 IA2 GR Instrument Panel J/B ECU–B 6 2G Engine Room R/B No. 3 3 EMPS 1 W 1 F11 1 F10 3 DC/DC 2 E6 RLY 2 E5 PGND 1 F13 F18 FL Block No. 2 MAIN J17 J/C A Battery PIG FL Block No. 1 1 2H W 2 1 E5 W–B 1 IG F12839 2001 PRIUS (RM778U) DI–485 DIAGNOSTICS – ELECTRIC MOTOR POWER STEERING INSPECTION PROCEDURE 1 Check voltage between terminals PIG and PGND of EMPS ECU connector. PREPARATION: 5/18/01Disconnect the connector from the EMPS ECU. CHECK: 5/18/01Turn the ignition switch ON and measure the voltage between terminals PIG and PGND of EMPS ECU connector. OK: Voltage: 9 – 14 V ON PGND PIG F16035 OK Check and replace EMPS ECU. NG 2 Check continuity between terminals PGND of EMPS ECU connector and body ground. LOCK PREPARATION: 5/18/01Connect the connector back to the EMPS ECU. CHECK: 5/18/01Measure the resistance between terminals PGND of EMPS ECU connector and body ground. OK: Resistance: 1 Ω or less PGND F12825 NG OK 2001 PRIUS (RM778U) 5/18/01 Repair or replace harness or connector. DI–486 DIAGNOSTICS 3 – ELECTRIC MOTOR POWER STEERING Check EMPS fuse. PREPARATION: 5/18/01Remove the EMPS fuse from engine room R/B No. 3. CHECK: 5/18/01Check continuity of EMPS fuse. OK: Continuity Engine Room R/B No. 3 EMPS Fuse F12862 NG Check for short circuit in harness and all components connected to EMPS fuse (See attached wiring diagram). OK Check for open and short circuit in harness and connector between EMPS ECU and battery (See page IN–41). 2001 PRIUS (RM778U) DI–488 DIAGNOSTICS – ELECTRIC MOTOR POWER STEERING DI7RA–01 DTC C1554/54 EMPS Relay Circuit CIRCUIT DESCRIPTION DTC No. C1554/54 DTC Detecting Condition Trouble Area
EMPS ECU
EMPS relay
EMPS relay circuit Open or short circuit is detected. WIRING DIAGRAM Engine Room R/B No. 3 EMPS Relay 3 3 B–R R–G 3 5 1 2 3 3 B 1 IM1 B GR 7 IM2 GR Instrument Panel J/B ECU–B 6 2G 1 2H Engine Room R/B No. 3 3 EMPS 1 W 1 F11 1 F10 3 DC/DC 2 E6 RLY 1 F13 F18 FL Block No. 2 MAIN J17 J/C A Battery PIG FL Block No. 1 W 2 1 E5 W–B 1 2 E5 PGND IG F12839 2001 PRIUS (RM778U) DI–489 DIAGNOSTICS – ELECTRIC MOTOR POWER STEERING INSPECTION PROCEDURE 1 Check voltage between terminals RLY and PGND of EMPS ECU connector. ON PREPARATION: Remove the EMPS ECU with connectors still connected. CHECK: Turn the ignition switch ON and measure the voltage between terminals RLY and PGND of EMPS ECU connector. OK: Voltage: 9 – 14 V RLY PGND F12828 OK Check or replace EMPS ECU. NG 2 Check EMPS relay. 5 3 1 2 Open PREPARATION: Remove the EMPS relay from the engine room R/B No. 3. CHECK: Check the continuity between each terminal of the EMPS relay. OK: 1 Terminals 1 and 2 Continuity (Reference value 80 Ω) Terminals 3 and 5 Open CHECK: (a) Apply battery positive voltage between terminals 1 and 2. (b) Check the continuity between the terminals. OK: 5 Terminals 3 and 5 3 Continuity 2 Continuity 1 5 3 2 F11788 2001 PRIUS (RM778U) Continuity DI–490 DIAGNOSTICS NG – ELECTRIC MOTOR POWER STEERING Replace EMPS relay. OK 3 Check ECU–B fuse. Instrument Panel J/B PREPARATION: Remove the ECU–B fuse from instrument panel J/B. CHECK: Check the continuity of ECU–B fuse. OK: Continuity ECU–B Fuse NG F12863 Check for short in harness and all components connected to ECU–B fuse (See attached wiring diagram). OK Check for open and short circuit in harness and connector between EMPS ECU and battery (See page IN–41). 2001 PRIUS (RM778U) DI–491 DIAGNOSTICS – ELECTRIC MOTOR POWER STEERING DI7RB–01 DTC C1556/56 P/S Warning Light Circuit CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition C1556/56 Trouble Area
Multiinformation display
EMPS ECU There is a malfunction in PS warning light circuit. WIRING DIAGRAM EMPS ECU Multiinformation Display 11 22 L 3 IP1 L 7 E6 Y WL Instrument Panel J/B 5 2A IG1 Relay GAUGE 3 5 F18 FL Block No. 2 MAIN 1 1 2H W FL Block No. 1 B–G 1 F13 DC/DC 1 F11 Battery F12840 2001 PRIUS (RM778U) DI–492 DIAGNOSTICS – ELECTRIC MOTOR POWER STEERING INSPECTION PROCEDURE 1 Check voltage between terminals WL of EMPS ECU connector and body ground. ON PREPARATION: Remove the EMPS ECU with connectors still connected. CHECK: Turn the ignition switch ON and measure the voltage between terminals WL of EMPS ECU connector and body ground. OK: Voltage: 9 – 14 V WL F12829 NG Check and replace EMPS ECU. OK 2 Check for open and short circuit in harness and connector between EMPS ECU and multiinformation display (See page IN–41). NG OK Check multiinformation display circuit (See page BE–97). 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–494 DIAGNOSTICS – ELECTRIC MOTOR POWER STEERING DI7RD–01 DTC Always ON Malfunction in EMPS ECU CIRCUIT DESCRIPTION DTC No. Always ON DTC Detecting Condition Trouble Area There is a malfunction in the EMPS ECU internal circuit.
Power source circuit
EMPS ECU
PS warning light circuit INSPECTION PROCEDURE 1 Is DTC output? Check DTC on page DI–460. YES Repair circuit indicated by output code. YES Check and replace EMPS ECU. NO 2 Is normal code displayed? NO 3 Does PS warning light goes off? YES NO 2001 PRIUS (RM778U) Check for open or short circuit in harness and connector between ECU–IG fuse and EMPS ECU (See page IN–41). DI–495 DIAGNOSTICS 4 – ELECTRIC MOTOR POWER STEERING Check battery positive voltage. PREPARATION: Start the engine. CHECK: Check the battery positive voltage. OK: Voltage: 9 – 14 V NG Check and repair charging system. OK 5 Check operation of PS warning light. PREPARATION: (a) Turn the ignition switch OFF. (b) Disconnect the connector from the EMPS ECU. (c) Turn the ignition switch ON. CHECK: Check the PS warning light goes OFF. OK Check and replace EMPS ECU. NG Check for short circuit in harness and connector between multiinformation display and EMPS ECU, multiinformation display and DLC3 (See page IN–41). 2001 PRIUS (RM778U) DI–496 DIAGNOSTICS – ELECTRIC MOTOR POWER STEERING DI7RE–01 Tc Terminal Circuit CIRCUIT DESCRIPTION Connecting terminals Tc and CG of the DLC3 causes the EMPS ECU to display the DTC by flashing the PS warning light. WIRING DIAGRAM EMPS ECU DLC3 J26 J/C Tc SG 13 P–B E 5 BR E 14 ID2 P–B 2 ID1 BR J16 J/C P–B 14 IO1 C C P–B 3 E6 Tc BR EB F12842 2001 PRIUS (RM778U) DI–497 DIAGNOSTICS – ELECTRIC MOTOR POWER STEERING INSPECTION PROCEDURE 1 Check voltage between terminals Tc and CG of DLC3. CHECK: Turn the ignition switch ON and measure the voltage between terminals Tc and CG of the DLC3. OK: Voltage: 9 – 14 V ON Tc CG F09678 OK If PS warning light does not blink even after Tc and CG are connected, EMPS ECU may be defective. NG 2 Turn the ignition switch OFF, and check for open and short circuit in harness and connector between EMPS ECU and DLC3, and DLC3 and body ground (See page IN–41). NG OK Check and replace EMPS ECU. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–498 DIAGNOSTICS – ELECTRIC MOTOR POWER STEERING DI7RF–01 Ts Terminal Circuit CIRCUIT DESCRIPTION The sensor check circuit detects abnormalities in the speed sensor signal which cannot be detected by the DTC check. Connecting terminals Ts and CG of the DLC3 starts the check. WIRING DIAGRAM EMPS ECU DLC3 Ts SG 14 GR–G 3 ID1 5 BR 14 ID2 J16 J/C GR–G BR B B 14 IO1 GR–G 9 E6 Ts BR EB F12844 2001 PRIUS (RM778U) DI–499 DIAGNOSTICS – ELECTRIC MOTOR POWER STEERING INSPECTION PROCEDURE 1 Check voltage between terminals Ts and CG of DLC3. CHECK: Turn the ignition switch ON and measure the voltage between terminals Ts and CG of the DLC3. OK: Voltage: 9 – 14 V ON Ts CG F09679 OK If PS warning light repeats turning ON and OFF even after Ts and CG are connected, EMPS ECU may be defective. NG 2 Turn the ignition switch OFF, and check for open and short circuit in harness and connector between EMPS ECU and DLC3, DLC3 and body ground (See page IN–41). NG OK Check and replace EMPS ECU. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–502 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6OY–07 PRE–CHECK 1. (a) (b) SRS WARNING LIGHT CHECK Turn the ignition switch to the ON position and check that the SRS warning light lights up. Check that the SRS warning light goes out after approx. 6 seconds. HINT:
H15218
2. (a) DLC3 CG Tc H10658 2001 PRIUS (RM778U) When the ignition switch is at ON and the SRS warning light remains on or flashes, the airbag sensor assembly has detected a malfunction code. If, after approx. 6 seconds have elapsed, the SRS warning light sometimes lights up or the SRS warning light lights up even when the ignition switch is OFF, a short in the SRS warning light circuit can be considered likely. Proceed to ”SRS warning light circuit malfunction” on page DI–632. DTC CHECK (Using diagnosis check wire) Present troubles codes: Output the DTC. (1) Turn the ignition switch to the ON position and wait for approx. 20 seconds. (2) Using SST, connect terminals Tc and CG of the DLC3. SST 09843–18020 NOTICE: Pay due attention to the terminal connecting position to avoid a malfunction. (b) Past troubles codes: Output the DTC. (1) Using service wire, connect terminals Tc and CG of the DLC3. SST 09843–18020 (2) Turn the ignition switch to the ON position and wait for approx. 20 seconds. NOTICE: Pay due attention to the terminal connecting position to avoid a malfunction. DI–503 DIAGNOSTICS SUPPLEMENTAL RESTRAINT SYSTEM (c) Normal Code 0.25 ON OFF 0.25 Code 11 and 31 0.5 – 4.0 2.5 ON OFF 1.5 0.5 DTC 11 Repeat DTC 31 AT0716 AB0056 H08231 TOYOTA Hand–held Tester DLC3 2001 PRIUS (RM778U) F12396 Read the DTC. Read the 2–digit DTC as indicated by the number of times the SRS warning light blinks. As an example, the blinking patterns, normal, 11 and 31 are shown in the illustration.
Normal code indication The light will blink 2 times per second.
Malfunction code indication The first blinking output indicates the first digit of a 2–digit DTC. After a 1.5–second pause, the second blinking output will indicate the second digit. If there are 2 or more codes, there will be a 2.5–second pause between each code. After all the codes have been output, there will be a 4.0–second pause and they will all be repeated. HINT:
In the event of a number of trouble codes, indication will start from the smallest numbered code.
If a DTC is not output or a DTC is output without terminal connection, proceed to the Tc terminal circuit inspection on page DI–636. 3. (a) (b) DTC CHECK (Using TOYOTA hand–held tester) Hook up the TOYOTA hand–held tester to the DLC3. Read the DTCs by following the prompts on the tester screen. HINT: Please refer to the TOYOTA hand–held tester operator’s manual for further details. 4. DTC CLEARANCE (Not using service wire) When the ignition switch is turned off, the diagnostic trouble code is cleared. HINT: DTC might not be cleared by turning the ignition switch OFF. In this case, proceed to the next step. 5. DTC CLEARANCE (Using service wire) (a) Connect the 2 service wires to terminals Tc and A/B of DLC3. (b) Turn the ignition switch to ON and wait for approx. 6 seconds. DI–504 DIAGNOSTICS (c) – SUPPLEMENTAL RESTRAINT SYSTEM Starting with the Tc terminal, ground alternately terminal Tc and terminal A/B twice each in cycles of 1.0 second. Make sure that the terminals are grounded. Ensure the terminal Tc remain grounded. HINT: When alternately grounding terminals Tc and A/B, release ground from one terminal and immediately ground the other terminal within an interval of 0.2 seconds. If DTCs are not cleared, repeat the above procedure until the codes are cleared. Terminal 1 second OFF Tc A/B 1 second (±0.5 sec.) (±0.5 sec.) Body Ground 1 5 3 Tc OFF A/B H10687 Body Ground 2 4 50 m sec. Several Seconds ON OFF 50 m sec. H15218 H15698 TOYOTA Hand–held Tester (d) Several seconds after doing the clearing procedure, the SRS warning light will blink in a 50 – m sec. cycle to indicate the codes which have been cleared. 6. (a) (b) DTC CLEARANCE (Using TOYOTA hand–held tester) Hook up the TOYOTA hand–held tester to the DLC3. Clear the DTCs by following the prompts on the tester screen. HINT: Please refer to the TOYOTA hand–held tester operation’s manual for further details. DLC3 2001 PRIUS (RM778U) F12396 DI–505 DIAGNOSTICS 7. – SUPPLEMENTAL RESTRAINT SYSTEM RELEASE METHOD OF AIRBAG ACTIVATION PREVENTION MECHANISM An airbag activation prevention mechanism is built into the connector for the squib circuit of the SRS. When release of the airbag activation prevention mechanism is directed in the troubleshooting procedure, as shown in the illustration of the connectors on the next pages, insert paper which has the same thickness as the male terminal between the terminal and the short spring. CAUTION: Never release the airbag activation prevention mechanism on the squib connector. NOTICE:
Do not release the airbag activation prevention mechanism unless specifically directed by the troubleshooting procedure.
If the inserted paper is too thick the terminal and short spring may be damaged, so always use paper with the same thickness as the male terminal. 2001 PRIUS (RM778U) DI–506 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM 7 8 9 11 Side Airbag Sensor Assembly (RH) Side Airbag Assembly (RH) (Squib) Seat Belt Pretensioner (RH) 10 Front Airbag Sensor (RH) 2 Airbag Sensor Assembly 6 1 3 Front Passenger Airbag Assembly (Squib) Spiral Cable 4 5 13 12 14 Steering Wheel Pad (Squib) Front Airbag Sensor (LH) Seat Belt Pretensioner (LH) 15 Side Airbag Assembly (LH) (Squib) 16 Side Airbag Sensor Assembly (LH) H15711 2001 PRIUS (RM778U) DI–507 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM Airbag Sensor Assembly Connector 2 Short Spring 1 Short Spring 3 Short Spring After Release Before Release Paper Connector 4 Connector 8 14 Short Spring Short Spring Before Release Paper After Release Paper H01356 H01233 AB0130 AB0045 H02249 H02248 AB0046 2001 PRIUS (RM778U) H11587 DI–508 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6OZ–06 DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the DTC check, check the circuit listed for that code in the table below (Proceed to the page given for that circuit.). DTC No. (See Page) Detection Item
Short in D squib circuit ON
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness ON
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness ON
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness ON
Front passenger airbag assembly (squib)
Airbag sensor assembly
Wire harness ON
Front passenger airbag assembly (squib)
Airbag sensor assembly
Wire harness ON
Front passenger airbag assembly (squib)
Airbag sensor assembly
Wire harness ON
Front passenger airbag assembly (squib)
Airbag sensor assembly
Wire harness ON
Side airbag assembly RH (squib)
Airbag sensor assembly
Wire harness Blink
Side airbag assembly RH (squib)
Airbag sensor assembly
Wire harness Blink
Short in side squib (RH) circuit (to ground)
Side airbag assembly RH (squib)
Airbag sensor assembly
Wire harness Blink
Short in side squib (RH) circuit (to B+)
Side airbag assembly RH (squib)
Airbag sensor assembly
Wire harness Blink
Short in side squib (LH) circuit
Side airbag assembly LH (squib)
Airbag sensor assembly
Wire harness Blink
Side airbag assembly LH (squib)
Airbag sensor assembly
Wire harness Blink
Open in D squib circuit B0101/14 (DI–515)
Short in D squib circuit (to ground) B0102/11 (DI–519)
Short in D squib circuit (to B+) B0103/12 (DI–523) B0106/54 (DI–531) B0107/51 (DI–534) B0108/52 (DI–537) B0110/43 (DI–540) B0111/44 (DI–544) B0112/41 (DI–550) B0113/42 (DI–550) B0115/47 (DI–553) B0116/48 (DI–557) SRS Warning Light
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness B0100/13 (DI–510) B0105/53 (DI–527) Trouble Area
Short in P squib circuit
Open in P squib circuit
Short in P squib circuit (to ground)
Short in P squib circuit (to B+)
Short in side squib (RH) circuit
Open in side squib (RH) circuit
Open in side squib (LH) circuit 2001 PRIUS (RM778U) DI–509 DIAGNOSTICS DTC No. (See Page) Detection Item – SUPPLEMENTAL RESTRAINT SYSTEM Trouble Area SRS Warning Light
Short in side squib (LH) circuit (to ground)
Side airbag assembly LH (squib)
Airbag sensor assembly
Wire harness Blink
Short in side squib (LH) circuit (to B+)
Side airbag assembly LH (squib)
Airbag sensor assembly
Wire harness Blink
Short in P/T squib (RH) circuit
Seat belt pretensioner RH (squib)
Airbag sensor assembly
Wire harness Blink
Seat belt pretensioner RH (squib)
Airbag sensor assembly
Wire harness Blink
Short in P/T squib (RH) circuit (to ground)
Seat belt pretensioner RH (squib)
Airbag sensor assembly
Wire harness Blink
Short in P/T squib (RH) circuit (to B+)
Seat belt pretensioner RH (squib)
Airbag sensor assembly
Wire harness Blink
Short in P/T squib (LH) circuit
Seat belt pretensioner LH (squib)
Airbag sensor assembly
Wire harness Blink
Seat belt pretensioner LH (squib)
Airbag sensor assembly
Wire harness Blink
Short in P/T squib (LH) circuit (to ground)
Seat belt pretensioner LH (squib)
Airbag sensor assembly
Wire harness Blink
Short in P/T squib (LH) circuit (to B+)
Seat belt pretensioner LH (squib)
Airbag sensor assembly
Wire harness Blink B1100/31 (DI–592)
Airbag sensor assembly malfunction
Airbag sensor assembly B1135/24 (DI–594)
Harf connection in airbag sensor assembly connector
Airbag sensor assembly
Wire harness Blink
Side airbag sensor assembly (RH) malfunction
Side airbag sensor assembly (RH)
Airbag sensor assembly
Wire harness Blink
Side airbag sensor assembly (LH) malfunction
Side airbag sensor assembly (LH)
Airbag sensor assembly
Wire harness Blink
Front airbag sensor (RH) malfunction
Front airbag sensor (RH)
Airbag sensor assembly
Instrument panel wire harness
Engine room No. 2 wire harness ON
Front airbag sensor (LH)
Airbag sensor assembly
Instrument panel wire harness
Engine room main wire harness ON B0117/45 (DI–560) B0118/46 (DI–563) B0130/63 (DI–566) B0131/64 (DI–570) B0132/61 (DI–573) B0133/62 (DI–576) B0135/73 (DI–579) B0136/74 (DI–583) B0137/71 (DI–586) B0138/72 (DI–589) B1140/32 (DI–597) B1141/33 (DI–605) B1156/B1157/ 15 (DI–613) B1158/B1159/ 16 (DI–621) Normall N (DI–629)
Open in P/T squib (RH) circuit
Open in P/T squib (LH) circuit
Front airbag sensor (LH) malfunction
System normal
Voltage source drop 2001 PRIUS (RM778U) ON –
Battery
Airbag sensor assembly OFF ON DI–510 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM HINT:


When the SRS warning light remains lit up and the DTC is the normal code, this means a voltage source drops. This malfunction is not stored in memory by the airbag sensor assembly and if the power source voltage returns to normal, the SRS warning light will automatically go out. When 2 or more codes are indicated, the codes will be displayed in numeral order starting from the lowest numbered code. If a code not listed on the chart is displayed, the airbag sensor assembly is faulty. 2001 PRIUS (RM778U) DI–512 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6P1–07 TERMINALS OF ECU B A19 A18 A17 6 A 5 4 3 2 1 9 8 7 6 5 4 3 2 1 25 24 23 22 21 20 19 18 12 11 10 9 8 7 B 6 5 4 3 2 1 17 16 15 14 13 12 12 11 10 9 8 7 28 27 26 A 11 10 A B H01357 No. Symbol A – Electrical Connector Check Mechanism Terminal Name B – Electrical Connector Check Mechanism A18 – 3 LA SRS Warning Light A18 – 5 IG2 Power Source A18 – 6 ACC Power Source A18 – 9 +SR Front Airbag Sensor (RH) A18 – 10 P+ Squib (Passenger) A18 – 11 P– Squib (Passenger) A18 – 12 SIL Diagnosis A18 – 13 D– Squib (Driver) A18 – 14 D+ Squib (Driver) A18 – 15 +SL Front Airbag Sensor (LH) A18 – 19 Tc A18 – 20 –SR A18 – 23 GSW2 A18 – 26 –SL Front Airbag Sensor (LH) A18 – 27 E1 Ground A18 – 28 E2 Ground A17 – 1 PL– Squib (Seat Belt Pretensioner, LH) A17 – 2 PL+ Squib (Seat Belt Pretensioner, LH) A17 – 5 SFL– Squib (Side, LH) A17 – 6 SFL+ Squib (Side, LH) A17 – 7 VUPL Side Airbag Sensor (LH) A17 – 9 ESL Side Airbag Sensor (LH) A17 – 10 SSL+ Side Airbag Sensor (LH) 2001 PRIUS (RM778U) Diagnosis Front Airbag Sensor (RH) ECM DI–513 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM No. Symbol A17 – 11 LBE+ Body ECU A17 – 12 SSL– Side Airbag Sensor (LH) A19 – 1 SFR+ Squib (Side, RH) A19 – 2 SFR– Squib (Side, RH) A19 – 5 PR+ Squib (Pretensioner, RH) A19 – 6 PR– Squib (Pretensioner, RH) A19 – 7 SSR– Side Airbag Sensor (RH) A19 – 9 SSR+ Side Airbag Sensor (RH) A19 – 10 ESR Side Airbag Sensor (RH) A19 – 12 VUPR Side Airbag Sensor (RH) 2001 PRIUS (RM778U) Terminal Name DI–515 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6P3–06 CIRCUIT INSPECTION DTC B0100/13 Short in D Squib Circuit CIRCUIT DESCRIPTION The D squib circuit consists of the airbag sensor assembly, spiral cable and steering wheel pad. It causes the airbag to deploy when the airbag deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0100/13 is recorded when a short is detected in the D squib circuit. DTC No. B0100/13 DTC Detecting Condition Trouble Area
Short circuit between D+ wire harness and D– wire harness of squib
D squib malfunction
Spiral cable malfunction
Airbag sensor assembly malfunction
Steering wheel pad (D squib)
Spiral cable
Airbag sensor assembly
Wire harness WIRING DIAGRAM Airbag Sensor Assembly D Squib 1 Y–B 2 Y 14 A18 D+ 13 A18 D– Spiral Cable H01451 2001 PRIUS (RM778U) DI–516 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–629). 2 Check D squib circuit. Airbag Sensor Assembly Spiral Cable D Squib D– D+ (–) H01001 H02142 PREPARATION: Release the airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the spiral cable (See page DI–497). CHECK: For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the resistance between D+ and D–. OK: Resistance: 1 MΩ or Higher (+) H02193 NG OK 2001 PRIUS (RM778U) Go to step 5. DI–517 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly Spiral Cable D Squib →← ON DTC B0100/13 DLC3 CG H01002 AB0119 H10600 Tc FI1390 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0100/13 is not output. HINT: Codes other than code B0100/13 may be output at this time, but they are not relevant to this check. H10598 NG OK 2001 PRIUS (RM778U) Replace airbag sensor assembly. DI–518 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check D squib. →← Spiral Cable D Squib Airbag Sensor Assembly ON DLC3 CG DTC B0100/13 Tc H01003 AB0119 H10600 FI1390 H10599 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the steering wheel pad connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (b) Turn the ignition switch to ON, and wait at least for 20 seconds. (c) Clear the DTC stored in memory (See page DI–497). (d) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (e) Turn the ignition switch to ON, and wait at least for 20 seconds. (f) Check the DTC (See page DI–497). OK: DTC B0100/13 is not output. HINT: Codes other than code B0100/13 may be output at this time, but they are not relevant to this check. NG Replace steering wheel pad. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 PRIUS (RM778U) DI–519 DIAGNOSTICS 5 – SUPPLEMENTAL RESTRAINT SYSTEM Check spiral cable. Airbag Sensor Assembly Spiral Cable ←→ D Squib D– D+ (–) PREPARATION: (a) Disconnect the connector between the airbag sensor assembly and the spiral cable. (b) Release the airbag activation prevention mechanism of the spiral cable connector on the airbag sensor assembly side (See page DI–497). CHECK: For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the resistance between D+ and D–. OK: Resistance: 1 MΩ or Higher (+) H01000 H02142 H02195 NG Repair or replace spiral cable. OK 6 Check harness between airbag sensor assembly and spiral cable. PREPARATION: Release the airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the spiral cable (See page DI–497). CHECK: For the connector (on the spiral cable side) between the airbag sensor assembly and the spiral cable, measure the resistance between D+ and D–. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly Spiral Cable D Squib D– (–) D+ (+) NG H01004 R14286 H01138 Repair or replace harness or connector between airbag sensor assembly and spiral cable. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 PRIUS (RM778U) DI–520 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6P4–04 DTC B0101/14 Open in D Squib Circuit CIRCUIT DESCRIPTION The D squib circuit consists of the airbag sensor assembly, spiral cable and steering wheel pad. It causes the airbag to deploy when the airbag deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0101/14 is recorded when an open is detected in the D squib circuit. DTC No. DTC Detecting Condition B0101/14 Trouble Area
Open circuit in D+ wire harness or D– wire harness of squib
D squib malfunction
Spiral cable malfunction
Airbag sensor assembly malfunction
Steering wheel pad (D squib)
Spiral cable
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–510. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–629). 2 Check D squib circuit. Airbag Sensor Assembly Spiral Cable D Squib CHECK: For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the resistance between D+ and D–. OK: Resistance: Below 1 Ω ←→ D– D+ (–) H01001 H02142 OK 2001 PRIUS (RM778U) (+) H02196 NG Go to step 5. DI–521 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly Spiral Cable D Squib →← ON D– D+ DLC3 CG DTC B0101/14 Tc H01002 H02144 AB0119 H10600 W02044 H10602 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect D+ and D– of the connector (on the spiral cable side) between the spiral cable and the steering wheel pad. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0101/14 is not output. HINT: Codes other than code B0101/14 may be output at this time, but they are not relevant to this check. NG OK 2001 PRIUS (RM778U) Replace airbag sensor assembly. DI–522 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check D squib. D Squib Spiral Cable Airbag Sensor Assembly →← ON DLC3 CG DTC B0101/14 Tc H01003 AB0119 H10600 W02044 H10603 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the steering wheel pad connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0101/14 is not output. HINT: Codes other than code B0101/14 may be output at this time, but they are not relevant to this check. NG Replace steering wheel pad. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 PRIUS (RM778U) DI–523 DIAGNOSTICS 5 – SUPPLEMENTAL RESTRAINT SYSTEM Check spiral cable. Spiral Cable ←→ D Squib D– Airbag Sensor Assembly D+ (–) PREPARATION: Disconnect the connector between the airbag sensor assembly and the spiral cable. CHECK: For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the resistance between D+ and D–. OK: Resistance: Below 1 Ω (+) H01000 H02142 H02195 NG Repair or replace spiral cable. OK 6 Check harness between airbag sensor assembly and spiral cable. Airbag Sensor Assembly Spiral Cable D Squib D– (–) H01004 R14286 CHECK: For the connector (on the spiral cable side) between the airbag sensor assembly and the spiral cable, measure the resistance between D+ and D–. OK: Resistance: Below 1 Ω D+ (+) NG Repair or replace harness or connector between airbag sensor assembly and spiral cable. H01138 OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 PRIUS (RM778U) DI–524 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6P5–04 DTC B0102/11 Short in D Squib Circuit (to Ground) CIRCUIT DESCRIPTION The D squib circuit consists of the airbag sensor assembly, spiral cable and steering wheel pad. It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0102/11 is recorded when a ground short is detected in the D squib circuit. DTC No. B0102/11 DTC Detecting Condition Trouble Area
Short circuit in D squib wire harness (to ground)
D squib malfunction
Spiral cable malfunction
Airbag sensor assembly malfunction
Steering wheel pad (D squib)
Spiral cable
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–510. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–629). 2 Check D squib circuit. CHECK: For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the resistance between D+ and body ground. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly Spiral Cable D Squib D+ (–) H01001 H02145 (+) H02198 NG OK 2001 PRIUS (RM778U) Go to step 5. DI–525 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Spiral Cable D Squib Airbag Sensor Assembly →← D– D+ DLC3 CG ON DTC B0102/11 Tc H01002 H02144 AB0118 H10600 W02042 H10605 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect D+ and D– of the connector (on the spiral cable side) between the spiral cable and the steering wheel pad. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0102/11 is not output. HINT: Codes other than code B0102/11 may be output at this time, but they are not relevant to this check. NG OK 2001 PRIUS (RM778U) Replace airbag sensor assembly. DI–526 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check D squib. →← Spiral Cable D Squib Airbag Sensor Assembly ON DLC3 CG DTC B0102/11 Tc H01003 AB0119 H10600 W02042 H10606 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the steering wheel pad connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0102/11 is not output. HINT: Codes other than code B0102/11 may be output at this time, but they are not relevant to this check. NG Replace steering wheel pad. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 PRIUS (RM778U) DI–527 DIAGNOSTICS 5 D Squib – SUPPLEMENTAL RESTRAINT SYSTEM Check spiral cable. PREPARATION: Disconnect the connector between the airbag sensor assembly and the spiral cable. CHECK: For the connector (on the spiral cable side) between the steering wheel pad and the spiral cable, measure the resistance between D+ and body ground. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly Spiral Cable ←→ D+ (–) (+) H01000 H02145 H02200 NG Repair or replace spiral cable. OK 6 Check harness between airbag sensor assembly and spiral cable. Airbag Sensor Assembly Spiral Cable D Squib CHECK: For the connector (on the spiral cable side) between the spiral cable and the airbag sensor assembly, measure the resistance between D+ and body ground. OK: Resistance: 1 MΩ or Higher D+ (–) (+) H01004 R14301 H06304 NG Repair or replace harness between airbag sensor assembly and spiral cable. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 PRIUS (RM778U) DI–528 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6P6–04 DTC B0103/12 Short in D Squib Circuit (to B+) CIRCUIT DESCRIPTION The D squib circuit consists of the airbag sensor assembly, spiral cable and steering wheel pad. It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0103/12 is recorded when a B+ short is detected in the D squib circuit. DTC No. DTC Detecting Condition B0103/12 Trouble Area
Short circuit in D squib wire harness (to B+)
D squib malfunction
Spiral cable malfunction
Airbag sensor assembly malfunction
Steering wheel pad (D squib)
Spiral cable
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–510. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–629). 2 Check D squib circuit. CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the voltage between D+ and body ground. OK: Voltage: 0 V ON Airbag Sensor Assembly Spiral Cable D Squib D+ (–) AB0119 H01001 H02146 OK 2001 PRIUS (RM778U) (+) NG H11570 Go to step 5. DI–529 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. →← D Squib Spiral Cable D– D+ DLC3 CG H01002 H02144 AB0119 H10600 W02043 Airbag Sensor Assembly ON DTC B0103/12 Tc H10608 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect D+ and D– of the connector (on the spiral cable side) between the spiral cable and the steering wheel pad. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0103/12 is not output. HINT: Codes other than code B0103/12 may be output at this time, but they are not relevant to this check. NG OK 2001 PRIUS (RM778U) Replace airbag sensor assembly. DI–530 DIAGNOSTICS 4 SUPPLEMENTAL RESTRAINT SYSTEM Check D squib. →← Spiral Cable Airbag Sensor Assembly D Squib ON DLC3 CG – DTC B0103/12 Tc H01003 AB0019 H10600 W02043 H10609 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the steering wheel pad connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0103/12 is not output. HINT: Codes other than code B0103/12 may be output at this time, but they are not relevant to this check. NG Replace steering wheel pad. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 PRIUS (RM778U) DI–531 DIAGNOSTICS 5 – SUPPLEMENTAL RESTRAINT SYSTEM Check spiral cable. Airbag Sensor Assembly Spiral Cable D Squib ←→ ON D+ (–) PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect the connector between the airbag sensor assembly and the spiral cable. CHECK: (a) Turn the ignition switch to ON. (b) For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the voltage between D+ and body ground. OK: Voltage: 0 V (+) H01000 AB0119 H02146 H02202 NG Repair or replace spiral cable. OK 6 Check harness between airbag sensor assembly and spiral cable. ON Airbag Sensor Assembly Spiral Cable D Squib CHECK: (a) Turn the ignition switch to ON. (b) For the connector (on the spiral cable side) between the spiral cable and airbag sensor assembly, measure the voltage between D+ and body ground. OK: Voltage: 0 V D+ (–) (+) NG AB0119 H01004 R14288 Repair or replace harness between airbag sensor assembly and spiral cable. H08261 OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 PRIUS (RM778U) DI–532 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6P7–06 DTC B0105/53 Short in P Squib Circuit CIRCUIT DESCRIPTION The P squib circuit consists of the airbag sensor assembly and front passenger airbag assembly. It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0105/53 is recorded when a short is detected in the P squib circuit. DTC No. B0105/53 DTC Detecting Condition Trouble Area
Short circuit in P squib wire harness
P squib malfunction
Airbag sensor assembly malfunction
Front passenger airbag assembly (P squib)
Airbag sensor assembly
Wire harness WIRING DIAGRAM Airbag Sensor Assembly P Squib 1 Y–R 10 A18 P+ 2 Y–G 11 A18 P– H01454 2001 PRIUS (RM778U) DI–533 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–629). 2 Check P squib circuit. PREPARATION: Release the airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the front passenger airbag assembly and the airbag sensor assembly (See page DI–497). CHECK: For the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly, measure the resistance between P+ and P–. OK: Resistance: 1 MΩ or Higher P Squib Airbag Sensor Assembly P– P+ (–) R14286 H02142 OK 2001 PRIUS (RM778U) (+) H02251 NG Repair or replace harness or connector between front passenger airbag assembly and airbag sensor assembly. DI–534 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P Squib Airbag Sensor Assembly →← ON DLC3 CG H01023 AB0119 H10600 DTC B0105/53 Tc H01077 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0105/53 is not output. HINT: Codes other than code B0105/53 may be output at this time, but they are not relevant to this check. H10611 NG OK 2001 PRIUS (RM778U) Replace airbag sensor assembly. DI–535 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P squib. P Squib →← Airbag Sensor Assembly ON DLC3 CG DTC B0105/53 Tc H01024 AB0119 H10600 H01077 H10612 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front passenger airbag assembly connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to LOOK, and wait at least for 20 seconds. (b) Turn the ignition switch to ON, and wait at least for 20 seconds. (c) Clear the DTC stored in memory (See page DI–497). (d) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (e) Turn the ignition switch to ON, and wait at least for 20 seconds. (f) Check the DTC (See page DI–497). OK: DTC B0105/53 is not output. HINT: Codes other than code B0105/53 may be output at this time, but they are not relevant to this check. NG Replace front passenger airbag assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 PRIUS (RM778U) DI–536 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6P8–01 DTC B0106/54 Open in P Squib Circuit CIRCUIT DESCRIPTION The P squib circuit consists of the airbag sensor assembly and front passenger airbag assembly. It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0106/54 is recorded when an open is detected in the P squib circuit. DTC No. B0106/54 DTC Detecting Condition Trouble Area
Open circuit in P+ wire harness or P– wire harness of squib
P squib malfunction
Airbag sensor assembly malfunction
Front passenger airbag assembly (P squib)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–527. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–629). 2 Check P squib circuit. CHECK: For the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly, measure the resistance between P+ and P–. OK: Resistance: Below 1 Ω P Squib Airbag Sensor Assembly P– (–) R14286 H02142 OK 2001 PRIUS (RM778U) P+ (+) NG H02251 Repair or replace harness or connector between front passenger airbag assembly and airbag sensor assembly. DI–537 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P Squib Airbag Sensor Assembly →← P– P+ DLC3 CG ON Code B0106/54 Tc H01023 H02144 AB0119 H10600 H01078 H10613 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect P+ and P– of the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0106/54 is not output. HINT: Codes other than code B0106/54 may be output at this time, but they are not relevant to this check. NG OK 2001 PRIUS (RM778U) Replace airbag sensor assembly. DI–538 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P squib. P Squib →← Airbag Sensor Assembly ON DLC3 CG DTC B0106/54 Tc H01024 AB0119 H10600 H01078 H10614 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front passenger airbag assembly connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0106/54 is not output. HINT: Codes other than code B0106/54 may be output at this time, but they are not relevant to this check. NG Replace front passenger airbag assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 PRIUS (RM778U) DI–539 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6P9–01 DTC B0107/51 Short in P Squib Circuit (to Ground) CIRCUIT DESCRIPTION The P squib circuit consists of the airbag sensor assembly and front passenger airbag assembly. It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0107/51 is recorded when ground short is detected in the P squib circuit. DTC No. B0107/51 DTC Detecting Condition Trouble Area
Short circuit in P squib wire harness (to ground)
P squib malfunction
Airbag sensor assembly malfunction
Front passenger airbag assembly (P squib)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–527. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–629). 2 Check P squib circuit. CHECK: For the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly, measure the resistance between P+ and body ground. OK: Resistance: 1 MΩ or Higher P Squib Airbag Sensor Assembly P+ (–) H01227 H02145 OK 2001 PRIUS (RM778U) (+) NG H02254 Repair or replace harness or connector between front passenger airbag assembly and airbag sensor assembly. DI–540 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P Squib Airbag Sensor Assembly →← ON P– P+ DLC3 CG H01023 H02144 AB0118 H10600 H01075 Code B0107/51 Tc H10615 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect P+ and P– of the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0107/51 is not output. HINT: Codes other than code B0107/51 may be output at this time, but they are not relevant to this check. NG OK 2001 PRIUS (RM778U) Replace airbag sensor assembly. DI–541 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P squib. P Squib →← Airbag Sensor Assembly ON DLC3 CG DTC B0107/51 Tc H01024 AB0119 H10600 H01075 H10616 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front passenger airbag assembly connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0107/51 is not output. HINT: Codes other than code B0107/51 may be output at this time, but they are not relevant to this check. NG Replace front passenger airbag assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 PRIUS (RM778U) DI–542 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6PA–01 DTC B0108/52 Short in P Squib Circuit (to B+) CIRCUIT DESCRIPTION The P squib circuit consists of the airbag sensor assembly and front passenger airbag assembly. It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0108/52 is recorded when a B+ short is detected in the P squib circuit. DTC No. B0108/52 DTC Detecting Condition Trouble Area
Short circuit in P squib wire harness (to B+)
P squib malfunction
Airbag sensor assembly malfunction
Front passenger airbag assembly (P squib)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–527. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–629). 2 Check P squib circuit. Airbag Sensor Assembly P Squib ON P+ (–) H01022 AB0119 H02146 OK 2001 PRIUS (RM778U) CHECK: (a) Turn the ignition switch to ON. (b) For the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly, measure the voltage between the P+ and body ground. OK: Voltage: 0 V (+) NG H04524 Repair or replace harness or connector between front passenger airbag assembly and airbag sensor assembly. DI–543 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P Squib Airbag Sensor Assembly →← ON P– P+ DLC3 CG DTC B0108/52 Tc H01023 H02144 AB0118 H10600 H01076 H10617 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect P+ and P– of the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0108/52 is not output. HINT: Codes other than code B0108/52 may be output at this time, but they are not relevant to this check. NG OK 2001 PRIUS (RM778U) Replace airbag sensor assembly. DI–544 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P squib. P Squib →← Airbag Sensor Assembly ON DLC3 CG DTC B0108/52 Tc H01024 AB0119 H10600 H01076 H10618 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front passenger airbag assembly connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0108/52 is not output. HINT: Codes other than code B0108/52 may be output at this time, but they are not relevant to this check. NG Replace front passenger airbag assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 PRIUS (RM778U) DI–545 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6PB–04 DTC B0110/43 Short in Side Squib (RH) Circuit CIRCUIT DESCRIPTION The side squib (RH) circuit consists of the airbag sensor assembly and side airbag assembly (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0110/43 is recorded when a short is detected in the side squib (RH) circuit. DTC No. B0110/43 DTC Detecting Condition Trouble Area
Short circuit between FR+ wire harness and FR– wire harness of squib
Side squib (RH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM Airbag Sensor Assembly Side Squib (RH) 1 Y–R 1 A19 SFR+ 2 Y–G 2 A19 SFR– H01454 2001 PRIUS (RM778U) DI–546 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–629). 2 Check side squib (RH) circuit. PREPARATION: Release the airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the side airbag assembly (RH) (See page DI–497). CHECK: For the connector (on the side airbag assembly side) between the side airbag assembly (RH) and the airbag sensor assembly, measure the resistance between FR+ and FR–. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly Squib (RH) FR– (–) H01019 H09668 FR+ (+) H12946 NG OK 2001 PRIUS (RM778U) Repair or replace harness or connector between side airbag assembly (RH) and airbag sensor assembly. DI–547 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly Squib (RH) →← ON DLC3 CG DTC B0110/43 Tc H01020 AB0119 H10600 H01069 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0110/43 is not output. HINT: Codes other than code B0110/43 may be output at this time, but they are not relevant to this check. H12017 NG OK 2001 PRIUS (RM778U) Replace airbag sensor assembly. DI–548 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (RH). Airbag Sensor Assembly Squib (RH) →← ON DTC B0110/43 DLC3 CG Tc H01020 AB0119 H10600 H01069 H12018 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag assembly (RH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to LOOK, and wait at least for 20 second. (b) Turn the ignition switch to ON, and wait at least for 20 seconds. (c) Clear the DTC stored in memory (See page DI–497). (d) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (e) Turn the ignition switch to ON, and wait at least for 20 seconds. (f) Check the DTC (See page DI–497). OK: DTC B0110/43 is not output. HINT: Codes other than code B0110/43 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 PRIUS (RM778U) DI–549 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6PC–01 DTC B0111/44 Open in Side Squib (RH) Circuit CIRCUIT DESCRIPTION The side squib (RH) circuit consists of the airbag sensor assembly and side airbag assembly (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0111/44 is recorded when an open is detected in the side squib (RH) circuit. DTC No. B0111/44 DTC Detecting Condition Trouble Area
Open circuit in FR+ wire harness or FR– wire harness of squib
Side squib (RH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–540. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–629). 2 Check front side squib (RH) circuit. CHECK: For the connector (on the front side airbag assembly side) between the front side airbag assembly (RH) and the airbag sensor assembly, measure the resistance between FR+ and FR–. OK: Resistance: Below 1 Ω Airbag Sensor Assembly Squib (RH) FR– (–) H01019 H09668 OK 2001 PRIUS (RM778U) FR+ (+) NG H12947 Repair or replace harness or connector between side airbag assembly (RH) and airbag sensor assembly. DI–550 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly Squib (RH) →← ON FR+ FR– DLC3 CG H01020 H09671 AB0119 H10600 H01070 DTC B0111/44 Tc H13039 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect FR+ and FR– of the connector (on the side airbag assembly side) between the side airbag assembly (RH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0111/44 is not output. HINT: Codes other than code B0111/44 may be output at this time, but they are not relevant to this check. NG OK 2001 PRIUS (RM778U) Replace airbag sensor assembly. DI–551 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (RH). Airbag Sensor Assembly Squib (RH) →← ON DLC3 CG DTC B0111/44 Tc H01021 AB0119 H10600 H01070 H12020 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front side airbag assembly (RH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0111/44 is not output. HINT: Codes other than code B0111/44 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 PRIUS (RM778U) DI–552 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6PD–01 DTC B0112/41 Short in Side Squib (RH) Circuit (to Ground) CIRCUIT DESCRIPTION The side squib (RH) circuit consists of the airbag sensor assembly and side airbag assembly (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0112/41 is recorded when ground short is detected in the side squib (RH) circuit. DTC No. B0112/41 DTC Detecting Condition Trouble Area
Short circuit in side squib (RH) wire harness (to ground)
Side squib (RH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–540. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–629). 2 Check side squib (RH) circuit. CHECK: For the connector (on the side airbag assembly side) between the side airbag assembly (RH) and the airbag sensor assembly, measure the resistance between FR+ and body ground. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly Squib (RH) FR+ (–) H01019 H09669 OK 2001 PRIUS (RM778U) (+) NG H12949 Repair or replace harness or connector between side airbag assembly (RH) and airbag sensor assembly. DI–553 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly Squib (RH) →← ON FR+ FR– DLC3 CG H01020 H09671 AB0119 H10600 H01070 DTC B0112/41 Tc H13040 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect FR+ and FR– of the connector (on the side airbag assembly side) between the side airbag assembly (RH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0112/41 is not output. HINT: Codes other than code B0112/41 may be output at this time, but they are not relevant to this check. NG OK 2001 PRIUS (RM778U) Replace airbag sensor assembly. DI–554 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (RH). Squib (RH) Airbag Sensor Assembly →← ON DLC3 CG DTC B0112/41 Tc H01021 AB0119 H10600 H01070 H12022 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag assembly (RH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0112/41 is not output. HINT: Codes other than code B0112/41 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 PRIUS (RM778U) DI–555 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6PE–01 DTC B0113/42 Short in Side Squib (RH) Circuit (to B+) CIRCUIT DESCRIPTION The side squib (RH) circuit consists of the airbag sensor assembly and side airbag assembly (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0113/42 is recorded when a B+ short is detected in the side squib (RH) circuit. DTC No. B0113/42 DTC Detecting Condition Trouble Area
Short circuit in side squib (RH) wire harness (to B+)
Side squib (RH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–540. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–497). 2 Check side squib (RH) circuit. CHECK: (a) Turn the ignition switch to ON. (b) For the connector (on the airbag sensor assembly side) between the side airbag assembly (RH) and the airbag sensor assembly, measure the voltage between FR+ and body ground. OK: Voltage: 0 V ON Airbag Sensor Assembly Squib (RH) FR+ (–) AB0119 H01019 H09670 OK 2001 PRIUS (RM778U) (+) NG H12951 Repair or replace harness or connector between side airbag assembly (RH) and airbag sensor assembly. DI–556 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly Squib (RH) →← ON FR+ FR– DLC3 CG H01020 H09671 AB0119 H10600 H01068 DTC B0113/42 Tc H13041 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect FR+ and FR– of the connector (on the front side airbag assembly side) between the front side airbag assembly (RH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0113/42 is not output. HINT: Codes other than code B0113/42 may be output at this time, but they are not relevant to this check. NG OK 2001 PRIUS (RM778U) Replace airbag sensor assembly. DI–557 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (RH). Squib (RH) Airbag Sensor Assembly →← ON DLC3 CG DTC B0113/42 Tc H01021 AB0119 H10600 H01068 H12024 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front side airbag assembly (RH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0113/42 is not output. HINT: Codes other than code B0113/42 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 PRIUS (RM778U) DI–558 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6PF–04 DTC B0115/47 Short in Side Squib (LH) Circuit CIRCUIT DESCRIPTION The side squib (LH) circuit consists of the airbag sensor assembly and side airbag assembly (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0115/47 is recorded when a short is detected in the side squib (LH) circuit. DTC No. DTC Detecting Condition Trouble Area B0115/47
Short circuit between FL+ wire harness and FL– wire harness of squib
Side squib (LH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM Airbag Sensor Assembly Side Squib (LH) 1 Y–R 6 A17 SFL+ 2 Y–G 5 A17 SFL– H01454 2001 PRIUS (RM778U) DI–559 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–629). 2 Check side squib (LH) circuit. PREPARATION: Release the airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the side airbag assembly (LH) (See page DI–497). CHECK: For the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly, measure the resistance between FL+ and FL–. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly Squib (LH) FL– (–) H01019 H09668 FL+ (+) H12953 NG OK 2001 PRIUS (RM778U) Repair or replace harness or connector between side airbag assembly (LH) and airbag sensor assembly. DI–560 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. →← Squib (LH) Airbag Sensor Assembly ON DLC3 CG DTC B0115/47 Tc H01017 AB0119 H10600 H01073 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0115/47 is not output. HINT: Codes other than code B0115/47 may be output at this time, but they are not relevant to this check. H12025 NG OK 2001 PRIUS (RM778U) Replace airbag sensor assembly. DI–561 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (LH). Squib (LH) →← Airbag Sensor Assembly ON DLC3 DTC B0115/47 CG Tc H01018 AB0119 H10600 H01073 H12026 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front side airbag assembly (LH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to LOOK, and wait at least for 20 second. (b) Turn the ignition switch to ON, and wait at least for 20 seconds. (c) Clear the DTC stored in memory (See page DI–497). (d) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (e) Turn the ignition switch to ON, and wait at least for 20 seconds. (f) Check the DTC (See page DI–497). OK: DTC B0115/47 is not output. HINT: Codes other than code B0115/47 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 PRIUS (RM778U) DI–562 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6PG–01 DTC B0116/48 Open in Side Squib (LH) Circuit CIRCUIT DESCRIPTION The side squib (LH) circuit consists of the airbag sensor assembly and side airbag assembly (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0116/48 is recorded when an open is detected in the side squib (LH) circuit. DTC No. B0116/48 DTC Detecting Condition Trouble Area
Open circuit in FL+ wire harness or FL– wire harness of squib
Side squib (LH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–553. INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–629) 2 Check side squib (LH) circuit. CHECK: For the connector (on the front side airbag assembly side) between the front side airbag assembly (LH) and the airbag sensor assembly, measure the resistance between FL+ and FL–. OK: Resistance: Below 1 Ω Airbag Sensor Assembly Squib (LH) FL– (–) H01019 H09668 OK 2001 PRIUS (RM778U) FL+ (+) NG H12954 Repair or replace harness or connector between side airbag assembly (LH) and airbag sensor assembly. DI–563 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. →← Squib (LH) Airbag Sensor Assembly ON FL– FL+ DLC3 CG DTC B0116/48 Tc H01017 H09671 AB0119 H10600 H01074 H13042 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect FL+ and FL– of the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least 2 seconds. CHECK: (a) Turn the ignition switch to ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0116/48 is not output. HINT: Codes other than code B0116/48 may be output at this time, but they are not relevant to this check. NG OK 2001 PRIUS (RM778U) Replace side airbag sensor assembly. DI–564 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (LH). Squib (LH) →← Airbag Sensor Assembly ON DLC3 CG DTC B0116/48 Tc H01018 AB0119 H10600 H01074 H12028 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag assembly (LH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0116/48 is not output. HINT: Codes other than code B0116/48 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 PRIUS (RM778U) DI–565 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6PH–01 DTC B0117/45 Short in Side Squib (LH) Circuit (to Ground) CIRCUIT DESCRIPTION The side squib (LH) circuit consists of the airbag sensor assembly and side airbag assembly (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0117/45 is recorded when ground short is detected in the side squib (LH) circuit. DTC No. B0117/45 DTC Detecting Condition Trouble Area
Short circuit in side squib (LH) wire harness (to ground)
Side squib (LH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–553. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–629). 2 Check side squib (LH) circuit. CHECK: For the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly, measure the resistance between FL+ and body ground. OK: Resistance: 1 MΩ or Higher Squib (LH) Airbag Sensor Assembly FL+ (–) H01016 H09669 OK 2001 PRIUS (RM778U) (+) NG H12956 Repair or replace harness or connector between side airbag assembly (LH) and airbag sensor assembly. DI–566 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Squib (LH) →← Airbag Sensor Assembly ON FL+ FL– DLC3 CG DTC B0117/45 Tc H01017 H09671 AB0119 H10600 H01071 H13043 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect FL+ and FL– of the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0117/45 is not output. HINT: Codes other than code B0117/45 may be output at this time, but they are not relevant to this check. NG OK 2001 PRIUS (RM778U) Replace airbag sensor assembly. DI–567 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (LH). Squib (LH) →← Airbag Sensor Assembly ON DLC3 CG DTC B0117/45 Tc H01018 AB0119 H10600 H01071 H12030 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front side airbag assembly (LH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0117/45 is not output. HINT: Codes other than code B0117/45 may be output at this time, but they are not relevant to this check. NG Replace front side airbag assembly (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 PRIUS (RM778U) DI–568 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6PI–01 DTC B0118/46 Short in Side Squib (LH) Circuit (to B+) CIRCUIT DESCRIPTION The side squib (LH) circuit consists of the airbag sensor assembly and side airbag assembly (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0118/46 is recorded when a B+ short is detected in the side squib (LH) circuit. DTC No. B0118/46 DTC Detecting Condition Trouble Area
Short circuit in side squib (LH) wire harness (to B+)
Side squib (LH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–553. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–629). 2 Check side squib (LH) circuit. ON Airbag Sensor Assembly Squib (LH) CHECK: (a) Turn the ignition switch to ON. (b) For the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly, measure the voltage between FL+ and body ground. OK: Voltage: 0 V FL+ (–) AB0119 H01016 H09670 OK 2001 PRIUS (RM778U) (+) NG H12958 Repair or replace harness or connector between side airbag assembly (LH) and airbag sensor assembly. DI–569 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. →← Squib (LH) Airbag Sensor Assembly ON FL+ FL– DLC3 H01017 H09671 H10600 – CG DTC B0118/46 Tc AB0119 H01072 H13044 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect FL+ and FL– of the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0118/46 is not output. HINT: Codes other than code B0118/46 may be output at this time, but they are not relevant to this check. NG OK 2001 PRIUS (RM778U) Replace airbag sensor assembly. DI–570 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (LH). Squib (LH) →← Airbag Sensor Assembly ON DLC3 CG DTC B0118/46 Tc H01018 AB0119 H10600 H01072 H13118 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag assembly (LH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0118/46 is not output. HINT: Codes other than code B0118/46 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 PRIUS (RM778U) DI–571 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6PJ–06 DTC B0130/63 Short in P/T Squib (RH) Circuit CIRCUIT DESCRIPTION The P/T squib (RH) circuit consists of the airbag sensor assembly and seat belt pretensioner (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0130/63 is recorded when a short is detected in the P/T squib (RH) circuit. DTC No. B0130/63 DTC Detecting Condition Trouble Area
Short circuit between PR+ wire harness and PR– wire harness of squib
P/T squib (RH) malfunction
Airbag sensor assembly malfunction
Seat belt pretensioner (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM Airbag Sensor Assembly P/T Squib (RH) 2 Y–B 5 A19 PR+ 1 Y 6 A19 PR– H01454 2001 PRIUS (RM778U) DI–572 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–629). 2 Check P/T squib (RH) circuit. P/T Squib (RH) Airbag Sensor Assembly PR+ PR– (+) H01019 H02141 PREPARATION: Release the airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the seat belt pretensioner (RH) (See page DI–497). CHECK: For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly, measure the resistance between PR+ and PR–. OK: Resistance: 1 MΩ or Higher (–) H02203 NG OK 2001 PRIUS (RM778U) Repair or replace harness or connector between seat belt pretensioner (RH) and airbag sensor assembly. DI–573 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly P/T Squib (RH) →← ON DLC3 CG DTC B0130/63 Tc H01020 AB0119 H10600 H01082 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0130/63 is not output. HINT: Codes other than code B0130/63 may be output at this time, but they are not relevant to this check. H10619 NG OK 2001 PRIUS (RM778U) Replace airbag sensor assembly. DI–574 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (RH). P/T Squib (RH) Airbag Sensor Assembly →← ON DLC3 CG DTC B0130/63 Tc H01021 AB0119 H10600 H01082 H10620 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (RH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to LOOK, and wait at least for 20 second. (b) Turn the ignition switch to ON, and wait at least for 20 seconds. (c) Clear the DTC stored in memory (See page DI–497). (d) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (e) Turn the ignition switch to ON, and wait at least for 20 seconds. (f) Check the DTC (See page DI–497). OK: DTC B0130/63 is not output. HINT: Codes other than code B0130/63 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 PRIUS (RM778U) DI–575 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6PK–04 DTC B0131/64 Open in P/T Squib (RH) Circuit CIRCUIT DESCRIPTION The P/T squib circuit (RH) consists of the airbag sensor assembly and seat belt pretensioner (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0131/64 is recorded when an open is detected in the P/T squib (RH) circuit. DTC No. B0131/64 DTC Detecting Condition Trouble Area
Open circuit in PR+ wire harness or PR– wire harness of squib
P/T squib (RH) malfunction
Airbag sensor assembly malfunction
Seat belt pretensioner (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–566. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–629). 2 Check P/T squib (RH) circuit. P/T Squib (RH) PR+ (+) H01019 H02141 OK 2001 PRIUS (RM778U) CHECK: For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly, measure the resistance between PR+ and PR–. OK: Resistance: Below 1 Ω Airbag Sensor Assembly PR– NG (–) H02205 Repair or replace harness or connector between seat belt pretensioner (RH) and airbag sensor assembly. DI–576 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly P/T Squib (RH) →← PR+ PR– DLC3 CG ON DTC B0131/64 Tc H01020 H02139 AB0119 H10600 H01083 H10621 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect PR+ and PR– of the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0131/64 is not output. HINT: Codes other than code B0131/64 may be output at this time, but they are not relevant to this check. NG OK 2001 PRIUS (RM778U) Replace airbag sensor assembly. DI–577 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (RH). P/T Squib (RH) Airbag Sensor Assembly →← ON DLC3 CG DTC B0131/64 Tc H01021 AB0119 H10600 H01083 H10622 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (RH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0131/64 is not output. HINT: Codes other than code B0131/64 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 PRIUS (RM778U) DI–578 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6PL–04 DTC B0132/61 Short in P/T Squib (RH) Circuit (to Ground) CIRCUIT DESCRIPTION The P/T squib (RH) circuit consists of the airbag sensor assembly and seat belt pretensioner (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0132/61 is recorded when a ground short is detected in the P/T squib (RH) circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in P/T squib (RH) wire harness (to ground)
P/T squib (RH) malfunction
Airbag sensor assembly malfunction B0132/61
Seat belt pretensioner (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–566. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–629). 2 Check P/T squib (RH) circuit. CHECK: For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly, measure the resistance between PR+ and body ground. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly P/T Squib (RH) PR+ (–) (+) NG H01019 H08392 OK 2001 PRIUS (RM778U) H08393 Repair or replace harness or connector between seat belt pretensioner (RH) and airbag sensor assembly. DI–579 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly P/T Squib (RH) →← PR+ PR– DLC3 CG ON DTC B0132/61 Tc H01020 H02139 AB0118 AB0119 H10600 H01079 H10623 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect PR+ and PR– of the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0132/61 is not output. HINT: Codes other than code B0132/61 may be output at this time, but they are not relevant to this check. NG OK 2001 PRIUS (RM778U) Replace airbag sensor assembly. DI–580 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (RH). P/T Squib (RH) Airbag Sensor Assembly →← ON DLC3 CG DTC B0132/61 Tc H01021 AB0119 H10600 H01079 H10624 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (RH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0132/61 is not output. HINT: Codes other than code B0132/61 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 PRIUS (RM778U) DI–581 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6PM–04 DTC B0133/62 Short in P/T Squib (RH) Circuit (to B+) CIRCUIT DESCRIPTION The P/T squib (RH) circuit consists of the airbag sensor assembly and seat belt pretensioner (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0133/62 is recorded when a B+ short is detected in the P/T squib (RH) circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in seat belt pretensioner (RH) wire harness (to B+)
P/T squib (RH) malfunction
Airbag sensor assembly malfunction B0133/62
Seat belt pretensioner (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–566. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–629). 2 Check P/T squib (RH) circuit. CHECK: (a) Turn the ignition switch to ON. (b) For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly, measure the voltage between PR+ and body ground. OK: Voltage: 0 V ON Airbag Sensor Assembly P/T Squib (RH) PR+ (–) (+) NG H01019 AB0119 H08394 OK 2001 PRIUS (RM778U) H08268 Repair or replace harness or connector between seat belt pretensioner (RH) and airbag sensor assembly. DI–582 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P/T Squib (RH) Airbag Sensor Assembly →← PR– PR+ ON DLC3 CG DTC B0133/62 Tc H01020 H02139 AB0119 H10600 H01081 H10625 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect PR+ and PR– of the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0133/62 is not output. HINT: Codes other than code B0133/62 may be output at this time, but they are not relevant to this check. NG OK 2001 PRIUS (RM778U) Replace airbag sensor assembly. DI–583 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (RH). Airbag Sensor Assembly P/T Squib (RH) →← ON DLC3 CG DTC B0133/62 Tc H01021 AB0119 H10600 H01081 H10626 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (RH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0133/62 is not output. HINT: Codes other than code B0133/62 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 PRIUS (RM778U) DI–584 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6PN–06 DTC B0135/73 Short in P/T Squib (LH) Circuit CIRCUIT DESCRIPTION The P/T squib (LH) circuit consists of the airbag sensor assembly and seat belt pretensioner (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0135/73 is recorded when a short is detected in the P/T squib (LH) circuit. DTC No. DTC Detecting Condition Trouble Area B0135/73
Short circuit between PL+ wire harness and PL– wire harness of squib
P/T squib (LH) malfunction
Airbag sensor assembly malfunction
Seat belt pretensioner (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM Airbag Sensor Assembly P/T Squib (LH) 2 Y–B 2 A17 PL+ 1 Y 1 A17 PL– H01454 2001 PRIUS (RM778U) DI–585 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–629). 2 Check P/T squib (LH) circuit. Airbag Sensor Assembly P/T Squib (LH) PL+ (+) H01016 H02141 PREPARATION: Release the airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the seat belt pretensioner (LH) (See page DI–497). CHECK: For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly, measure the resistance between PL+ and PL–. OK: Resistance: 1 MΩ or Higher PL– (–) H02211 NG OK 2001 PRIUS (RM778U) Repair or replace harness or connector between seat belt pretensioner (LH) and airbag sensor assembly. DI–586 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P/T Squib (LH) →← Airbag Sensor Assembly ON DLC3 CG DTC B0135/73 Tc H01017 AB0119 H10600 H01086 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0135/73 is not output. HINT: Codes other than code B0135/73 may be output at this time, but they are not relevant to this check. H10627 NG OK 2001 PRIUS (RM778U) Replace airbag sensor assembly. DI–587 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (LH). →← P/T Squib (LH) Airbag Sensor Assembly ON DLC3 CG DTC B0135/73 Tc H01018 AB0119 H10600 H01086 H10628 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (LH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to LOOK, and wait at least for 20 second. (b) Turn the ignition switch to ON, and wait at least for 20 seconds. (c) Clear the DTC stored in memory (See page DI–497). (d) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (e) Turn the ignition switch to ON, and wait at least for 20 seconds. (f) Check the DTC (See page DI–497). OK: DTC B0135/73 is not output. HINT: Codes other than code B0135/73 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 PRIUS (RM778U) DI–588 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6PO–04 DTC B0136/74 Open in P/T Squib (LH) Circuit CIRCUIT DESCRIPTION The P/T squib circuit (LH) consists of the airbag sensor assembly and seat belt pretensioner (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0136/74 is recorded when an open is detected in the P/T squib (LH) circuit. DTC No. B0136/74 DTC Detecting Condition Trouble Area
Open circuit in PL+ wire harness or PL– wire harness of squib
P/T squib (LH) malfunction
Airbag sensor assembly malfunction
Seat belt pretensioner (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–579. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–629). 2 Check P/T squib (LH) circuit. P/T Squib (LH) PL+ (+) H01016 H02141 OK 2001 PRIUS (RM778U) CHECK: For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly, measure the resistance between PL+ and PL–. OK: Resistance: Below 1 Ω Airbag Sensor Assembly PL– (–) NG H02213 Repair or replace harness or connector between seat belt pretensioner (LH) and airbag sensor assembly. DI–589 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P/T Squib (LH) Airbag Sensor Assembly PL+ PL– ON DLC3 CG H01017 H02139 AB0119 H10600 H01087 DTC B0136/74 Tc H10629 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect PL+ and PL– of the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0136/74 is not output. HINT: Codes other than code B0136/74 may be output at this time, but they are not relevant to this check. NG OK 2001 PRIUS (RM778U) Replace airbag sensor assembly. DI–590 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (LH). P/T Squib (LH) →← Airbag Sensor Assembly ON DLC3 CG DTC B0136/74 Tc H01018 AB0119 H10600 H01087 H10630 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (LH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0136/74 is not output. HINT: Codes other than code B0136/74 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 PRIUS (RM778U) DI–591 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6PP–04 DTC B0137/71 Short in P/T Squib (LH) Circuit (to Ground) CIRCUIT DESCRIPTION The P/T squib (LH) circuit consists of the airbag sensor assembly and seat belt pretensioner (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0137/71 is recorded when a ground short is detected in the P/T squib (LH) circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in P/T squib (LH) wire harness (to ground)
P/T squib (LH) malfunction
Airbag sensor assembly malfunction B0137/71
Seat belt pretensioner (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–579. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–629). 2 Check P/T squib (LH) circuit. CHECK: For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly, measure the resistance between PL+ and body ground. OK: Resistance: 1 MΩ or Higher P/T Squib (LH) Airbag Sensor Assembly PL+ (–) (+) NG H01016 H08392 OK 2001 PRIUS (RM778U) H08396 Repair or replace harness or connector between seat belt pretensioner (LH) and airbag sensor assembly. DI–592 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. →← P/T Squib (LH) PL+ PL– DLC3 CG Airbag Sensor Assembly ON DTC B0137/71 Tc H01017 H02139 AB0119 H10600 H01084 H10631 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect PL+ and PL– of the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0137/71 is not output. HINT: Codes other than code B0137/71 may be output at this time, but they are not relevant to this check. NG OK 2001 PRIUS (RM778U) Replace airbag sensor assembly. DI–593 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (LH). →← P/T Squib (LH) Airbag Sensor Assembly ON DLC3 CG DTC B0137/71 Tc H01018 AB0118 AB0119 H10600 H01084 H10632 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (LH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0137/71 is not output. HINT: Codes other than code B0137/71 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 PRIUS (RM778U) DI–594 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6PQ–04 DTC B0138/72 Short in P/T Squib (LH) Circuit (to B+) CIRCUIT DESCRIPTION The P/T squib (LH) circuit consists of the airbag sensor assembly and seat belt pretensioner (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0138/72 is recorded when a B+ short is detected in the P/T squib (LH) circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in seat belt pretensioner (LH) wire harness (to B+)
P/T squib (LH) malfunction
Airbag sensor assembly malfunction B0138/72
Seat belt pretensioner (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–579. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–629). 2 Check P/T squib (LH) circuit. ON Airbag Sensor Assembly P/T Squib (LH) PL+ (–) CHECK: (a) Turn the ignition switch to ON. (b) For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly, measure the voltage between PL+ and body ground. OK: Voltage: 0 V (+) NG AB0119 H01016 H08394 OK 2001 PRIUS (RM778U) H08269 Repair or replace harness or connector between seat belt pretensioner (LH) and airbag sensor assembly. DI–595 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P/T Squib (LH) →← Airbag Sensor Assembly PL+ PL– DLC3 CG ON DTC B0138/72 Tc H01017 H02139 AB0119 H10600 H01085 H10633 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect PL+ and PL– of the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0138/72 is not output. HINT: Codes other than code B0138/72 may be output at this time, but they are not relevant to this check. NG OK 2001 PRIUS (RM778U) Replace airbag sensor assembly. DI–596 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (LH). P/T Squib (LH) →← Airbag Sensor Assembly ON DLC3 CG DTC B0138/72 Tc H01018 AB0119 H10600 H01085 H10634 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (LH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B0138/72 is not output. HINT: Codes other than code B0138/72 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 PRIUS (RM778U) DI–597 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6PR–01 DTC B1100/31 Airbag Sensor Assembly Malfunction CIRCUIT DESCRIPTION The airbag sensor assembly consists of a airbag sensor, safing sensor, drive circuit, diagnosis circuit and ignition control, etc. It receives signals from the airbag sensor, judges whether or not the SRS must be activated, and detects diagnosis system malfunction. DTC B1100/31 is recorded when occurrence of a malfunction in the airbag sensor assembly is detected. DTC No. DTC Detecting Condition Trouble Area
Airbag sensor assembly malfunction B1100/31
Airbag sensor assembly INSPECTION PROCEDURE HINT: When a malfunction code other than code B1100/31 is displayed at the same time, first repair the malfunction indicated by the malfunction code other than code B1100/31. 1 Prepare for inspection (See step 1 on page DI–629). 2 Check voltage at IG1 and IG2 of airbag sensor assembly. ON Airbag Sensor Assembly IG1 (–) IG2 (+) AB0119 H01298 OK 2001 PRIUS (RM778U) H01299 CHECK: (a) Turn the ignition switch to ON. (b) Measure the voltage between body ground and each of terminals IG1 and IG2 of the airbag sensor assembly connector. OK: Voltage: 10 – 14 V NG Check that an abnormality occurs on the battery and charging system. DI–598 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Is DTC B1100/31 output again? ON DLC3 CG DTC B1100/31 Tc AB0119 H10600 FI1394 H10635 YES Replace airbag sensor assembly. 2001 PRIUS (RM778U) PREPARATION: Clear the DTC (See step 5 on page DI–497). CHECK: (a) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (b) Turn the ignition switch to ON, and wait at least for 20 seconds. (c) Repeat operation in step (a) and (b) at least 5 times. (d) Check the DTC (See page DI–497). HINT: Codes other than code B1100/31 may be output at this time, but they are not relevant to this check. NO Using simulation method, reproduce malfunction symptoms (See page IN–30). DI–599 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI7IA–06 DTC B1135/24 Harf Connection in Airbag Sensor Assembly Connector CIRCUIT DESCRIPTION The airbag sensor assembly detects partial connection of connector. For details of the function of each component, see OPERATION on page RS–2. DTC B1135/24 is recorded when the airbag sensor assembly detects an open in the electrical connection chech mechanism of the airbag sensor connector or in the airbag sensor circuit. DTC No. B1135/24 DTC Detecting Condition Trouble Area
Malfunction of electrical connection check mechanism of airbag sensor assembly connector
Airbag sensor assembly malfunction
Electrical connection check mechanism
Airbag sensor assembly INSPECTION PROCEDURE 1 Are connector of center airbag sensor assembly properly connected? NG Connect connectors. OK 2 Prepare for inspection (See step 1 on page DI–629). 2001 PRIUS (RM778U) DI–600 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. ON Airbag Sensor Assembly DTC B1135/24 DLC3 CG Tc H15222 PREPARATION: (a) Connect the connectors to the airbag sensor assembly. (b) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (b) Turn the ignition switch to ON, and wait at least for 20 seconds. (c) Clear the DTC stored in memory (See page DI–497). (d) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (e) Turn the ignition switch to ON, and wait at least for 20 seconds. (f) Check the DTC (See page DI–497). OK: DTC B1135/24 is not output. HINT: Codes other than code B1135/24 may be output at this time, but they are not relevant to this check. NG Go to the next step. OK From the results of the inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 PRIUS (RM778U) DI–601 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check disconnection detection pin in the center airbag sensor assembly connector. CHECK: With 3 connectors connected to the sensor assembly, place tester leads onto any 2 of 3 disconnection detection pins and check for continuity. OK: Continuity NG Go to the next step. H14983 OK From the results of the inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 5 Perform a visual check of the disconnection detection pin. OK: No deformation is identified. HINT: Compare it with the other 2 connector pins. NG H15243 OK Replace airbag sensor assembly. 2001 PRIUS (RM778U) Repair or replace airbag sensor assembly connector. DI–602 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6PS–03 DTC B1140/32 Side Airbag Sensor Assembly (RH) Malfunction CIRCUIT DESCRIPTION The side airbag sensor assembly (RH) consists of the safing sensor, diagnosis circuit and lateral deceleration sensor, etc. It receives signals from the lateral deceleration sensor, judges whether or not the SRS must be activated, and detects diagnosis system malfunction. DTC B1140/32 is recorded when occurrence of a malfunction in the side airbag sensor assembly (RH) is detected. DTC No. B1140/32 DTC Detecting Condition Trouble Area
Side airbag sensor assembly (RH)
Wire harness
Airbag sensor assembly
Side airbag sensor assembly (RH) malfunction WIRING DIAGRAM Side Airbag Sensor Assembly (RH) 4 ESR FSR SSR+ VUPR Airbag Sensor Assembly 10 GR A19 ESR 3 LG 7 A19 SSR– 2 L–Y 9 A19 SSR+ 1 P 12 A19 VUPR H01450 2001 PRIUS (RM778U) DI–603 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Is DTC B1140/32 out put? ON DLC3 DTC B1140/32 CG Tc AB0119 H10600 H09528 H12032 CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). HINT: Codes other than code B1140/32 may be output at this time, but they are not relevant to this check. YES The malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. NO 2 Is connector of side airbag sensor assembly (RH) properly connected? 3 Prepare for inspection (See step 1 on DI–629). 2001 PRIUS (RM778U) DI–604 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness. PREPARATION: (a) Disconnect the side airbag sensor assembly (RH) connector. (b) Using a service wire, connect SSR+ and ESR of the connector (on the side airbag sensor assembly side) between the side airbag sensor assembly (RH) and airbag sensor assembly. CHECK: For the connector (on the airbag sensor assembly side) between the side airbag sensor assembly (RH) and the airbag sensor assembly, measure the resistance between SSR+ and ESR. OK: Resistance: Below 1 Ω Side Airbag Sensor Assembly (RH) ←→ Airbag Sensor Assembly Airbag Sensor Assembly SSR+ ESR (+) (–) H01015 H16250 H01036 OK 2001 PRIUS (RM778U) SSR+ ESR H16301 NG Repair or replace harness or connector between side airbag sensor assembly (RH) and airbag sensor assembly. DI–605 DIAGNOSTICS 5 – SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness. PREPARATION: Using a service wire, connect VUPR and FSR of the connector (on the side airbag sensor assembly side) between the side airbag sensor assembly (RH) and airbag sensor assembly. CHECK: For the connector (on the airbag sensor assembly side) between the side airbag sensor assembly (RH) and the airbag sensor assembly, measure the resistance between VUPR and FSR. OK: Resistance: Below 1 Ω Side Airbag Sensor Assembly (RH) Airbag Sensor Assembly Airbag Sensor Assembly VUPR FSR VUPR (+) FSR (–) H01015 H16249 H01037 OK 2001 PRIUS (RM778U) H16302 NG Repair or replace harness or connector between side airbag sensor assembly (RH) and airbag sensor assembly. DI–606 DIAGNOSTICS 6 – SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness (to ground). Side Airbag Sensor Assembly (RH) CHECK: For the connector (on the airbag sensor assembly side) between the side airbag sensor assembly (RH) and the airbag sensor assembly, measure the resistance between body ground and each of SSR+, VUPR and FSR. OK: Resistance: Below 1 Ω Airbag Sensor Assembly Airbag Sensor Assembly VUPR FSR (+) (–) H01013 H01038 SSR+ H01162 NG Repair or replace harness or connector between side airbag sensor assembly (RH) and airbag sensor assembly. OK 7 Check wire harness (to B+). ON Side Airbag Sensor Assembly (RH) Airbag Sensor Assembly Airbag Sensor Assembly SSR+ AB0119 H01013 H01039 (–) VUPR (+) OK 2001 PRIUS (RM778U) CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the airbag sensor assembly side) between the side airbag sensor assembly (RH) and the airbag sensor assembly, measure the voltage between the body ground and each of SSR+, VUPR, ESR and FSR. OK: Voltage: 0 V FSR ESR H08270 NG Repair or replace harness or connector between side airbag sensor assembly (RH) and airbag sensor assembly. DI–607 DIAGNOSTICS 8 – SUPPLEMENTAL RESTRAINT SYSTEM Is DTC B1140/32 out put again? Side Airbag Sensor Assembly (RH) Airbag Sensor Assembly →← →← ON DLC3 CG DTC B1140/32 Tc H01012 AB0119 H10600 H01065 H13119 PREPARATION: (a) Connect the connector to the side airbag sensor assembly (RH). (b) Connect the connector to the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B1140/32 is not output. HINT: Codes other than code B1140/32 may be output at this time, but they are not relevant to this check. NG Go to step 9. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 PRIUS (RM778U) DI–608 DIAGNOSTICS 9 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Side Airbag Sensor Assembly (RH) Airbag Sensor Assembly →← ON DLC3 CG DTC B1140/32 Tc H01012 AB0119 H10600 H01065 H13119 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Disconnect the side airbag sensor (RH) from the connector and connect the side airbag sensor (LH) to the connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B1140/32 is not output. HINT: Codes other than code B1140/32 may be output at this time, but they are not relevant to this check. NG OK 2001 PRIUS (RM778U) Replace airbag sensor assembly. DI–609 DIAGNOSTICS 10 – SUPPLEMENTAL RESTRAINT SYSTEM Check side airbag sensor assembly (RH). →← Side Airbag Sensor Assembly (RH) Airbag Sensor Assembly ON DLC3 CG DTC B1141/33 Tc H01007 AB0119 H10600 H01066 H12033 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag sensor (RH) to the connector that the side airbag sensor (LH) was connected to. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B1141/33 is not output. HINT: Codes other than code B1141/33 may be output at this time, but they are not relevant to this check. NG Replace side airbag sensor assembly (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 PRIUS (RM778U) DI–610 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6PT–03 DTC B1141/33 Side Airbag Sensor Assembly (LH) Malfunction CIRCUIT DESCRIPTION The side airbag sensor assembly (LH) consists of the safing sensor, diagnosis circuit and lateral deceleration sensor, etc. It receives signals from the lateral deceleration sensor, judges whether or not the SRS must be activated, and detects diagnosis system malfunction. DTC B1141/33 is recorded when occurrence of a malfunction in the side airbag sensor assembly (LH) is detected. DTC No. B1141/33 DTC Detecting Condition Trouble Area
Side airbag sensor assembly (LH) malfunction
Side airbag sensor assembly (LH)
Wire harness
Airbag sensor assembly WIRING DIAGRAM Side Airbag Sensor Assembly (LH) Airbag Sensor Assembly 4 GR–L 9 A17 ESL 3 LG–B 12 A17 SSL– 2 L–W 10 A17 SSL+ 1 P–L 7 A17 VUPL ESL FSL SSL+ VUPL H01450 2001 PRIUS (RM778U) DI–611 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Is DTC B1141/33 out put? ON DLC3 CG DTC B1141/33 Tc AB0119 H10600 H09530 CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). HINT: Codes other than code B1141/33 may be output at this time, but they are not relevant to this check. H12034 YES The malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. NO 2 Is connector of side airbag sensor assembly (LH) properly connected? 3 Prepare for inspection (See step 1 on page DI–629). 2001 PRIUS (RM778U) DI–612 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness. ←→ Side Airbag Sensor Assembly (LH) SSL+ Airbag Sensor Assembly Airbag Sensor Assembly ESL PREPARATION: (a) Disconnect the side airbag sensor assembly (LH). (b) Using a service wire, connect SSL+ and ESL of the connector (on the side airbag sensor assembly side) between the side airbag sensor assembly (LH) and the airbag sensor assembly. CHECK: For the connector (on the airbag sensor assembly side) between the side airbag sensor assembly (LH) and the airbag sensor assembly, measure the resistance between SSL+ and ESL. OK: Resistance: Below 1 Ω ESL (+) H01010 H16250 H01050 (–) OK 2001 PRIUS (RM778U) SSL+ H16303 NG Repair or replace harness or connector between side airbag sensor assembly (LH) and airbag sensor assembly. DI–613 DIAGNOSTICS 5 – SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness. PREPARATION: Using a service wire, connect VUPL and FSL of the connector (on the side airbag sensor assembly side) between the side airbag sensor assembly (LH) and the airbag sensor assembly. CHECK: For the connector (on the airbag sensor assembly side) between the side airbag sensor assembly (LH) and the airbag sensor assembly, measure the resistance between VUPL and FSL. OK: Resistance: Below 1 Ω Side Airbag Sensor Assembly (LH) Airbag Sensor Assembly Airbag Sensor Assembly VUPL FSL FSL (+) H01010 H16249 H01051 VUPL (–) OK 2001 PRIUS (RM778U) H16304 NG Repair or replace harness or connector between side airbag sensor assembly (LH) and airbag sensor assembly. DI–614 DIAGNOSTICS 6 – SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness (to ground). CHECK: For the connector (on the airbag sensor assembly side) between the side airbag sensor assembly (LH) and the airbag sensor assembly, measure the resistance between body ground and each of SSL+, VUPL and FSL. OK: Resistance: 1 MΩ or Higher SIde Airbag Sensor Assembly (LH) Airbag Sensor Assembly Airbag Sensor Assembly SSL+ VUPL (+) (–) FSL H01008 H01052 H01168 NG Repair or replace harness or connector between side airbag sensor assembly (LH) and airbag sensor assembly. OK 7 ON Check wire harness (to B+). Side Airbag Sensor Assembly (LH) Airbag Sensor Assembly Airbag Sensor Assembly FSL SSL+ ESL VUPL H01008 AB0119 H01053 (+) CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the airbag sensor assembly side) between the side airbag sensor assembly (LH) and the airbag sensor assembly, measure the voltage between body ground and each of SSL+, ESL, VUPL and FSL. OK: Voltage: 0 V (–) H08271 NG OK 2001 PRIUS (RM778U) Repair or replace harness or connector between side airbag sensor assembly (LH) and airbag sensor assembly. DI–615 DIAGNOSTICS 8 – SUPPLEMENTAL RESTRAINT SYSTEM Is DTC B1141/33 out put again? Side Airbag Sensor Assembly (LH) →← Airbag Sensor Assembly →← ON DLC3 CG DTC B1141/33 Tc H01007 AB0119 H10600 H01066 H12033 PREPARATION: (a) Connect the connector to the side airbag sensor assembly (LH). (b) Connect the connector to the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B1141/33 is not output. HINT: Codes other than code B1141/33 may be output at this time, but they are not relevant to this check. NO Go to step 9. YES From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 PRIUS (RM778U) DI–616 DIAGNOSTICS 9 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. →← Side Airbag Sensor Assembly (RH) Airbag Sensor Assembly ON DLC3 CG – DTC B1141/33 Tc H01007 AB0119 H10600 H01066 H12033 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Disconnect the side airbag sensor (LH) from the connector and connect the side airbag sensor (RH) to the connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B1141/33 is not output. HINT: Codes other than code B1141/33 may be output at this time, but they are not relevant to this check. NG OK 2001 PRIUS (RM778U) Replace airbag sensor assembly. DI–617 DIAGNOSTICS 10 – SUPPLEMENTAL RESTRAINT SYSTEM Check side airbag sensor assembly (LH). Side Airbag Sensor Assembly (LH) Airbag Sensor Assembly →← ON DLC3 CG DTC B1140/32 Tc H01012 AB0119 H10600 H01065 H13119 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag sensor (LH) to the connector that the side airbag sensor (RH) was connected to. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B1140/32 is not output. HINT: Codes other than code B1140/32 may be output at this time, but they are not relevant to this check. NG Replace side airbag sensor assembly (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 PRIUS (RM778U) DI–618 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6PW–06 DTC B1156/B1157/15 Front Airbag Sensor (RH) Malfunction CIRCUIT DESCRIPTION The front airbag sensor (RH) circuit consists of the airbag sensor assembly and front airbag sensor (RH). For details of the function of each component, see OPERATION on page RS–2. DTC B1156/B1157/15 is recorded when a malfunction is detected in the front airbag sensor (RH) circuit. DTC No. B1156/B1157/15 DTC Detecting Condition Trouble Area
Front airbag sensor (RH)
Airbag sensor assembly
Wire harness
Engine room No. 2 wire harness
Front airbag sensor (RH) malfunction WIRING DIAGRAM Front Airbag Sensor (RH) +SR Airbag Sensor Assembly B–W 2 3 IL1 4 –SR BR–W 1 IL1 B–W 9 A18 +SR BR–W 20 A18 –SR H16901 2001 PRIUS (RM778U) DI–619 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–629). 2 Check wire harness (to B+). Airbag Sensor Assembly Front Airbag Sensor (RH) ON (+) H03355 AB0119 H03363 (–) Airbag Sensor Assembly CHECK: (a) Turn the ignition switch to ON. (b) For the connector (on the airbag sensor assembly side) between the front airbag sensor (RH) and the airbag sensor assembly, measure the voltage between body ground and each of +SR and –SR. OK: Voltage: Below 1 V +SR –SR H03445 NG Go to step 8. OK 3 Check wire harness (to ground). Airbag Sensor Assembly Front Airbag Sensor (RH) (+) (–) H03353 H03361 OK 2001 PRIUS (RM778U) Airbag Sensor Assembly CHECK: For the connector (on the airbag sensor assembly side) between the front airbag sensor (RH) and the airbag sensor assembly, measure the resistance between body ground and each of +SR and –SR. OK: Resistance: 1 MΩ or Higher +SR –SR H03443 NG Go to step 9. DI–620 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness. Front Airbag Sensor (RH) Airbag Sensor Assembly Airbag Sensor Assembly CHECK: For the connector (on the airbag sensor assembly side) between the front airbag sensor (RH) and the airbag sensor assembly, measure the resistance between +SR and –SR. OK: Resistance: 1 MΩ or Higher +SR (+) (–) –SR H03355 H03356 H09518 NG Go to step 10. OK 5 Check wire harness. Front Airbag Sensor (RH) Airbag Sensor Assembly +SR –SR (+) (–) H03353 H03360 H03356 Airbag Sensor Assembly +SR PREPARATION: Using a service wire, connect +SR and –SR of the connector (on the front airbag sensor (RH) side) between the airbag sensor assembly and the front airbag sensor (RH). CHECK: For the connector (on the airbag sensor assembly side) between the front airbag sensor (RH) and the airbag sensor assembly, measure the resistance between +SR and –SR. OK: Resistance: Below 1 Ω –SR H16296 NG OK 2001 PRIUS (RM778U) Go to step 11. DI–621 DIAGNOSTICS 6 SUPPLEMENTAL RESTRAINT SYSTEM Check front airbag sensor (RH). Front Airbag Sensor (RH) Airbag Sensor Assembly +SR H04504 H01062 – (+) OK 2001 PRIUS (RM778U) CHECK: For the connector of the front airbag sensor (RH), measure the resistance between +SR and –SR. OK: Resistance: 300 – 1500 Ω –SR (–) H08346 NG Replace front airbag sensor (RH). DI–622 DIAGNOSTICS 7 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Front Airbag Sensor (RH) Airbag Sensor Assembly →← →← ON DLC3 CG DTC B1156/B1157/15 Tc H02757 AB0119 H10600 H01063 H10638 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front airbag sensor (RH) connector and airbag sensor assembly connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B1156/B1157/15 is not output. HINT: Codes other than code B1156/B1157/15 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 PRIUS (RM778U) DI–623 DIAGNOSTICS 8 – SUPPLEMENTAL RESTRAINT SYSTEM Check engine room No. 2 wire harness (to B+). Front Airbag Sensor (RH) ←→ Airbag Sensor Assembly Engine Room No. 2 Wire Harness ON +SR (–) –SR (+) PREPARATION: Disconnect the engine room No. 2 wire harness connector on the airbag sensor assembly side. CHECK: (a) Turn the ignition switch to ON. (b) For the connector (on the RH front door wire harness side) between the airbag sensor assembly and the engine room No. 2 wire harness, measure the voltage between body ground and each of +SR and –SR. OK: Voltage: Below 1 V NG H03354 AB0119 H03364 H08348 Repair or replace engine room No. 2 wire harness. OK Repair or replace harness or connector between airbag sensor assembly and engine room No. 2 wire harness. 9 Check engine room No. 2 wire harness (to ground). Front Airbag Sensor (RH) Airbag Sensor Assembly Engine Room No. 2 Wire Harness (–) +SR –SR PREPARATION: Disconnect the engine room No. 2 wire harness connector on the airbag sensor assembly side. CHECK: For the connector (on the engine room No. 2 wire harness side) between the airbag sensor assembly and the engine room No. 2 wire harness, measure the resistance between body ground and each of +SR and –SR. OK: Resistance: 1 MΩ or Higher (+) NG H03354 H03362 Repair or replace engine room No. 2 wire harness. H08349 OK Repair or replace harness or connector between airbag sensor assembly and engine room No. 2 wire harness. 2001 PRIUS (RM778U) DI–624 DIAGNOSTICS 10 – SUPPLEMENTAL RESTRAINT SYSTEM Check engine room No. 2 wire harness. Front Airbag Sensor (RH) Engine Room No. 2 Wire Harness ←→ +SR (+) H03354 H09507 Airbag Sensor Assembly –SR PREPARATION: Disconnect the engine room No. 2 wire harness connector on the airbag sensor assembly side. CHECK: For the connector (on the engine room No. 2 wire harness side) between the airbag sensor assembly and the engine room No. 2 wire harness, measure the resistance between +SR and –SR. OK: Resistance: 1 MΩ or Higher (–) H08351 NG Repair or replace engine room No. 2 wire harness. OK Repair or replace harness or connector between airbag sensor assembly and engine room No. 2 wire harness. 2001 PRIUS (RM778U) DI–625 DIAGNOSTICS 11 – SUPPLEMENTAL RESTRAINT SYSTEM Check engine room No. 2 wire harness. Engine Room No. 2 Wire Harness Front Airbag Sensor (RH) Airbag Sensor Assembly ←→ +SR –SR +SR (+) H03352 H03360 H09507 –SR (–) PREPARATION: (a) Disconnect the engine room No. 2 wire harness connector on the airbag sensor assembly side. (b) Using a service wire, connect +SR and –SR of the connector (on the engine room No. 2 wire harness side) between the engine room No. 2 wire harness and the front airbag sensor (RH). CHECK: For the connector (on the engine room No. 2 wire harness side) between the airbag sensor assembly and the engine room No. 2 wire harness, measure the resistance between +SR and –SR. OK: Resistance: Below 1 Ω H08350 NG Repair or replace engine room No. 2 wire harness. OK Repair or replace harness or connector between airbag sensor assembly and engine room No. 2 wire harness. 2001 PRIUS (RM778U) DI–626 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6PX–06 DTC B1158/B1159/16 Front Airbag Sensor (LH) Malfunction CIRCUIT DESCRIPTION The front airbag sensor (LH) circuit consists of the airbag sensor assembly and front airbag sensor (LH). For details of the function of each component, see OPERATION on page RS–2. DTC B1158/B1159/16 is recorded when malfunction is detected in the front airbag sensor (LH) circuit. DTC No. B1158/B1159/16 DTC Detecting Condition Trouble Area
Front airbag sensor (LH)
Airbag sensor assembly
Wire harness
Engine room main wire harness
Front airbag sensor (LH) malfunction WIRING DIAGRAM Front Airbag Sensor (LH) Airbag Sensor Assembly 2 W–R 1 IL1 W–R 1 BR 2 IL1 BR +SL –SL 15 A18 +SL 26 A18 –SL H16901 2001 PRIUS (RM778U) DI–627 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–629). 2 Check wire harness (to B+). Airbag Sensor Assembly Front Airbag Sensor (LH) ON Airbag Sensor Assembly +SL (+) NG (–) H03355 AB0119 H08065 CHECK: (a) Turn the ignition switch to ON. (b) For the connector (on the airbag sensor assembly side) between the front airbag sensor (LH) and the airbag sensor assembly, measure the voltage between body ground and each of +SL and –SL. OK: Voltage: Below 1 V –SL Go to step 8. H10972 OK 3 Check wire harness (to ground). Airbag Sensor Assembly Front Airbag Sensor (LH) (+) H03355 H08399 (–) OK 2001 PRIUS (RM778U) Airbag Sensor Assembly CHECK: For the connector (on the airbag sensor assembly side) between the front airbag sensor (LH) and the airbag sensor assembly, measure the resistance between body ground and each of +SL and –SL. OK: Resistance: 1 MΩ or Higher +SL NG –SL H10973 Go to step 9. DI–628 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness. Front Airbag Sensor (LH) Airbag Sensor Assembly CHECK: For the connector (on the airbag sensor assembly side) between the front airbag sensor (LH) and the airbag sensor assembly, measure the resistance between +SL and –SL. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly (+) +SL (–) –SL H03355 H08058 H10974 NG Go to step 10. OK 5 Check wire harness. Front Airbag Sensor (LH) Airbag Sensor Assembly +SL –SL Airbag Sensor Assembly (+) +SL (–) –SL H03353 H03360 H03356 PREPARATION: Using a service wire, connect +SL and –SL of the connector (on the front airbag sensor (LH) side) between the airbag sensor assembly and the front airbag sensor (LH). CHECK: For the connector (on the airbag sensor assembly side) between the front airbag sensor (LH) and the airbag sensor assembly, measure the resistance between +SL and –SL. OK: Resistance: Below 1 Ω H16296 NG OK 2001 PRIUS (RM778U) Go to step 11. DI–629 DIAGNOSTICS 6 – SUPPLEMENTAL RESTRAINT SYSTEM Check front airbag sensor (LH). Airbag Sensor Assembly CHECK: For the connector (on the front airbag sensor (LH)), measure the resistance between +SL and –SL. OK: Resistance: 300 – 1500 Ω Front Airbag Sensor (LH) +SL H04504 H01062 (+) OK 2001 PRIUS (RM778U) –SL (–) H08346 NG Replace front airbag sensor (LH). DI–630 DIAGNOSTICS 7 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Front Airbag Sensor (LH) Airbag Sensor Assembly →← →← ON DTC B1158/B1159/16 DLC3 CG Tc H02757 AB0119 H10600 H01064 H10647 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front airbag sensor (LH) connector and airbag sensor assembly connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI–497). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI–497). OK: DTC B1158/B1159/16 is not output. HINT: Codes other than code B1158/B1159/16 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 PRIUS (RM778U) DI–631 DIAGNOSTICS 8 – SUPPLEMENTAL RESTRAINT SYSTEM Check engine room main wire harness (to B+). Front Airbag Sensor (LH) ←→ Airbag Sensor Assembly Engine Room Main Wire Harness ON +SL –SL PREPARATION: Disconnect the engine room main wire harness connector on the airbag sensor assembly side. CHECK: (a) Turn the ignition switch to ON. (b) For the connector (on the LH front door wire harness side) between the airbag sensor assembly and the engine room main wire harness, measure the voltage between body ground and each of +SL and –SL. OK: Voltage: Below 1 V (+) (–) NG H03354 H16253 H16297 Repair or replace engine room main wire harness. OK Repair or replace harness or connector between airbag sensor assembly and engine room main wire harness. 9 Check engine room main wire harness (to ground). Front Airbag Sensor (LH) Airbag Sensor Assembly Engine Room Main Wire Harness +SL (–) –SL PREPARATION: Disconnect the engine room main wire harness connector on the airbag sensor assembly side. CHECK: For the connector (on the engine room main wire harness side) between the airbag sensor assembly and the engine room main wire harness, measure the resistance between body ground and each of +SL and –SL. OK: Resistance: 1 MΩ or Higher (+) NG H03354 H16252 Repair or replace engine room main wire harness. H16298 OK Repair or replace harness or connector between airbag sensor assembly and engine room main wire harness. 2001 PRIUS (RM778U) DI–632 DIAGNOSTICS 10 SUPPLEMENTAL RESTRAINT SYSTEM Check engine room main wire harness. Front Airbag Sensor (LH) Engine Room Main Wire Harness ←→ Airbag Sensor Assembly +SL H03354 H16251 – (+) –SL (–) PREPARATION: Disconnect the engine room main wire harness connector on the airbag sensor assembly side. CHECK: For the connector (on the engine room main wire harness side) between the airbag sensor assembly and the engine room main wire harness, measure the resistance between +SL and –SL. OK: Resistance: 1 MΩ or Higher H16299 NG Repair or replace engine room main wire harness. OK Repair or replace harness or connector between airbag sensor assembly and engine room main wire harness. 2001 PRIUS (RM778U) DI–633 DIAGNOSTICS 11 – SUPPLEMENTAL RESTRAINT SYSTEM Check engine room main wire harness. Engine Room Main Wire Harness Front Airbag Sensor (LH) Airbag Sensor Assembly ←→ +SL –SL +SL (+) H03352 H03360 H16251 –SL (–) PREPARATION: (a) Disconnect the engine room main wire harness connector on the airbag sensor assembly side. (b) Using a service wire, connect +SL and –SL of the connector (on the engine room main wire harness side) between the engine room main wire harness and the front airbag sensor (LH). CHECK: For the connector (on the engine room main wire harness side) between the airbag sensor assembly and the engine room main wire harness, measure the resistance between +SL and –SL. OK: Resistance: Below 1 Ω H16300 NG Repair or replace engine room main wire harness. OK Repair or replace harness or connector between airbag sensor assembly and engine room main wire harness. 2001 PRIUS (RM778U) DI–634 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6PY–07 DTC Normal Source Voltage Drop CIRCUIT DESCRIPTION The SRS is equipped with a voltage–increase circuit (DC–DC converter) in the airbag sensor assembly in case the source voltage drops. When the battery voltage drops, the voltage–increase circuit (DC–DC converter) functions to increase the voltage of the SRS to normal voltage. The diagnosis system malfunction display for this circuit is different from other circuits that is when the SRS warning light remains lit up and the DTC is a normal code, source voltage drop is indicated. Malfunction in this circuit is not recorded in the airbag sensor assembly, and the source voltage returns to normal, the SRS warning light automatically goes off. DTC No. Diagnosis (Normal) Source voltage drop WIRING DIAGRAM Airbag Sensor Assembly 5 Instrument Panel J/B B–W 5 2 2B 2E ACC Relay 10A SRS ACC 1 2H W 5 8 2C 4 2E 3 8 1 B–O A18 IG2 6 GR A18 ACC W–B 2K 2 5A AM1 3 2B Ignition Switch P–L ACC 3 IG2 6 Engine Room J/B B 15A AM2 2 1B 9 1J 1 W–R 2G 1 FL Block No. 1 1 F12 1 F11 F13 100A DC/DC AM1 2 W–R AM2 7 Instrument Panel J/B W–G A 2 2C J11 J/C FL Block No. 2 B–G 120A 1 MAIN Battery ID H15524 2001 PRIUS (RM778U) DI–635 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection. LOCK Airbag Sensor Assembly P Squib D Squib Spiral Cable Front Airbag Sensor (LH) Front Airbag Sensor (RH) P/T Squib (LH) Side Airbag Sensor (LH) Side Squib (LH) P/T Squib (RH) Side Airbag Sensor (RH) Side Squib (RH) H06508 H01026 2001 PRIUS (RM778U) H06509 PREPARATION: (a) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (b) Remove the steering wheel pad (See page SR–6). (c) Disconnect the connector of the front passenger airbag assembly (See page RS–27). (d) Disconnect the connector of the side airbag assembly RH and LH (See page RS–40). (e) Disconnect the connector of the seat belt pretensioner RH and LH (See page BO–90). (f) Disconnect the connectors of the airbag sensor assembly (See page RS–52). (g) Disconnect the connector of the front airbag sensor RH and LH (See page RS–57). (h) Disconnect the connector of the side airbag sensor assembly RH and LH (See page RS–62). CAUTION: Store the steering wheel pad, front passenger airbag assembly and side airbag assemlby with the front surface facing upward. DI–636 DIAGNOSTICS 2 – SUPPLEMENTAL RESTRAINT SYSTEM Check source voltage. ON Airbag Sensor Assembly IG1 (–) ACC (+) AB0119 H01298 H01299 PREPARATION: Connect negative (–) terminal cable to the battery. CHECK: (a) Turn ignition switch ON. (b) Measure the voltage between body ground and each of IG1 and IG2 on the sensor and operate electric system (defogger, wiper, headlight, heater blower, etc.). OK: Voltage: 10 – 14 V NG Check harness between battery and airbag sensor assembly, and check battery and charging system. OK 3 Does SRS warning light turn off? ON H01249 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Connect the steering wheel pad connector. (c) Connect the front passenger airbag assembly connector. (d) Connect the side airbag assembly connectors. (e) Connect the seat belt pretensioner connectors. (f) Connect the airbag sensor assembly connectors. (g) Connect the front airbag sensor connectors. (h) Connect the side airbag sensor assembly connectors. (i) Turn the ignition switch to ON. CHECK: Operate electric system (defogger, wiper, headlight, heater blower, etc.) and check that SRS warning light goes off. NO Check for DTCs. If a DTC is output, perform troubleshooting for the DTC. If a normal code is output, replace airbag sensor assembly. YES From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 PRIUS (RM778U) DI–637 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI7QT–01 SRS Warning Light Circuit Malfunction CIRCUIT DESCRIPTION The SRS warning light is located on the combination meter. When the SRS is normal, the SRS warning light lights up for approx. 6 seconds after the ignition switch is turned from the LOCK position to ON position, and then turns off automatically. If there is a malfunction in the SRS, the SRS warning light lights up to inform the driver of the abnormality. When terminals Tc and CG of the DLC3 are connected, the DTC is displayed by blinking the SRS warning light. WIRING DIAGRAM 15 Combination Meter L L 9 2A 1 2E 4 2B 5 GR–R C11 C GR–R J28 B J/C C J27 GR–R J26 J/C B–G 1 120A MAIN W DC/DC I15 Ignition S/W F18 FL Block No. 2 P–L 2 3 LA 1 2H 8 2C 6 AB B–Y 10A ACC 2 2D 8 2K 8 2A Fl Block No. 1 1 1 100A F11 F13 3 A18 B–Y DLC3 16 C10 B Airbag Sensor Assembly Instrument Panel J/B C10 W–B ACC Relay 3 5 A 1 J11 J/C 2 5A AM1 W–G 3 2B Battery ID H15525 2001 PRIUS (RM778U) DI–638 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE Always lights up, when ignition switch is in LOCK position 1 Prepare for inspection (See step 1 on page DI–629). 2 Does SRS warning light turn off? Airbag Sensor Assembly LOCK AB0117 H01293 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Disconnect the airbag sensor assembly connector. (d) Connect negative (–) terminal cable to the battery. CHECK: Check operation of SRS warning light. H01295 NO YES Replace airbag sensor assembly. 2001 PRIUS (RM778U) Check SRS warning light circuit or terminal A/B circuit of DLC3. DI–639 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM Does not light up, when ignition switch is turned to ON 1 Check AM2 Fuse. Fuse N14677 PREPARATION: Remove the AM2 fuse. CHECK: Check continuity of the AM2 fuse. OK: Continuity HINT:
Fuse may be burnt out even if it appears to be OK during visual inspection.
If fuse is OK, install it. NG Go to step 4. OK 2 Prepare for inspection (See step 1 on page DI–629). 3 Check SRS warning light circuit. Airbag Sensor Assembly ON (+) LA (–) AB0119 H01300 H01301 PREPARATION: (a) Disconnect the airbag sensor assembly connector. (b) Connect negative (–) terminal cable to the battery. (c) Turn the ignition switch to ON. CHECK: Measure the voltage between body ground and LA terminal of the harness side connector of the airbag sensor assembly. OK: Voltage: 10 – 14 V NG OK Replace airbag sensor assembly. 2001 PRIUS (RM778U) Check combination meter or repair SRS warning light circuit. DI–640 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Is new AM2 fuse burnt out again? NO YES Check harness between AM2 fuse and SRS warning light. 2001 PRIUS (RM778U) Using simulation method, reproduce malfunction symptoms (See page IN–30). DI–641 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI6Q0–06 Tc Terminal Circuit CIRCUIT DESCRIPTION By connecting terminals Tc and CG of the DLC3 the airbag sensor assembly is set in the DTC output mode. The DTCs are displayed by blinking the SRS warning light. WIRING DIAGRAM Airbag Sensor Assembly J24 J/C W–B W–B A 2D J26 J/C DLC3 A CG 4 Tc P–B P–B 13 E E 19 A18 Tc 8 Instrument Panel J/B 2K 8 W–B A J11 J/C ID H15526 2001 PRIUS (RM778U) DI–642 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE If the DTC is not displayed, do the following troubleshooting. 1 Does SRS warning light light up for approx. 6 seconds? LOCK ON AB0117 AB0119 H15218 PREPARATION: Check operation of the SRS warning light after ignition switch is turned from LOCK position to ON position. H15700 NO Check SRS warning light system (See page DI–632). YES 2 Check voltage between terminals Tc and CG of DLC3. PREPARATION: Turn the ignition switch to ON. CHECK: Measure the voltage between terminals Tc and CG of DLC3. OK: Voltage: 10 – 14 V ON CG (–) AB0119 H10688 (+) Tc H10654 OK NG 2001 PRIUS (RM778U) Go to step 4. DI–643 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check voltage between terminal Tc of DLC3 and body ground. CHECK: Measure the voltage between terminal Tc of DLC3 and body ground. OK: Voltage: 10 – 14 V ON Tc (–) (+) OK AB0119 H10689 H10656 Check harness between terminal E1 of DLC3 and body ground. NG 4 Check airbag sensor assembly. LOCK ON Airbag Sensor Assembly Tc AB0117 AB0119 H01302 H12918 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Disconnect the airbag sensor assembly connector. (d) Insert service wire into terminal Tc from back side as shown in the illustration. (e) Connect the airbag sensor assembly connector with service wire. (f) Connect negative (–) terminal cable to the battery. (g) Turn the ignition switch to ON and wait at least for 20 seconds. (h) Connect service wire of terminal Tc to body ground. CHECK: Check operation of the SRS warning light. OK: SRS waning light comes on. NOTICE: Pay due attention to the terminal connecting position to avoid a malfunction. OK NG Replace airbag sensor assembly. 2001 PRIUS (RM778U) Check harness between the airbag sensor assembly and DLC3. DI–644 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM If the DTC is displayed without a DTC check procedure, perform the following troubleshooting. 1 Check resistance between terminal Tc of airbag sensor assembly and body ground. Airbag Sensor Assembly LOCK Tc (–) (+) AB0119 H01304 H01305 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Disconnect the airbag sensor assembly connector. CHECK: Check resistance between terminal Tc of the airbag sensor assembly connector and body ground. OK: Resistance: 1 MΩ or Higher NG OK Replace airbag sensor assembly. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–647 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI7NG–01 Hand–held tester PRE–CHECK 1. (a) (b) (c) Break–out–box N09348 2. (a) (b) DLC3 F12396 (a) 2001 PRIUS (RM778U) USING HAND–HELD TESTER Hook up the hand–held tester to the DLC3. Monitor the ECU data by following the prompts on the tester screen. HINT: Hand–held tester has a ”Snapshot” function which records the monitored data. Please refer to the hand–held tester operator’s manual for further details. 3. DTC CLEARANCE DTC can be deleted using a hand–held tester. If there is no hand–held tester or it cannot be used, disconnect the auxiliary battery for 1 min. or more and connect it again. 4. N17520 ECU TERMINAL VALUES MEASUREMENT BY USING BREAK–OUT–BOX AND HAND–HELD TESTER Hook up the break–out–box and hand–held tester to the vehicle. Read the ECU input/output values by following the prompts on the tester screen. Please refer to the hand–held tester has a ”Snapshot” function. This records the measured data and is effective in the diagnosis of intermittent problems. PROBLEM SYMPTOM CONFIRMATION (ROAD TEST) Inspect the SET switch. (1) Push the main switch ON. (2) Drive at a desired speed (40 km/h (25 mph) or higher). (3) Press the control switch to the SET/COAST. (4) After releasing the switch, check that the vehicle cruises at the desired speed. DI–648 DIAGNOSTICS Inspect the ACCEL switch. (1) Push the main switch ON. (2) Drive at a desired speed (40 km/h (25 mph) or higher). (3) Check that the vehicle speed increases while the control switch is turned to RES/ACC, and that the vehicle cruises at the set speed when the switch is released. (4) Momentarily press the control switch upward in the RES/ACC and then immediately release it. Check that the vehicle speed increases by about 1.5 km/h (Tap–up function). (c) Inspect the COAST switch. (1) Push the main switch ON. (2) Drive at a desired speed (40 km/h (25 mph) or higher). (3) Check that the vehicle speed decreases while the control switch is turned to SET/COAST, and the vehicle cruises at the set speed when the switch is released. (4) Momentarily press the control switch is turned to SET/COAST, and then immediately release it. Check that the vehicle speed decreases by about 1.5 km/h (Tap–down function). (d) Inspect the CANCEL switch. (1) Push the main switch ON. (2) Drive at a desired speed (40 km/h (25 mph) or higher). (3) When operating one of the followings, check that the cruise control system is cancelled and that the normal driving mode is reset.
Depress the brake pedal
Shift to except D range (A/T)
Push the main switch OFF N17520 2001 PRIUS (RM778U) CRUISE CONTROL SYSTEM (b) N17520 N17520 – DI–649 DIAGNOSTICS – CRUISE CONTROL SYSTEM
(e) Inspect the RESUME switch. (1) Push the main switch ON. (2) Drive at a desired speed (40 km/h (25 mph) or higher). (3) When operating one of the followings, check that the cruise control system is cancelled and that the normal driving mode is reset.
Depress the brake pedal
Shift to except D range (A/T)
Pull the cruise control switch to CANCEL (4) After the control switch is turned to RES/ACC at the driving speed of more than 40 km/h (25 mph), check that the vehicle restores the speed prior to the cancellation. 5. INPUT SIGNAL CHECK (Using hand–held tester) Connect the hand–held tester to DLC3 Check the control switch (MAIN, CANCEL, SET/COAST, RES/ACC) N17520 (a) (b) N17520 2001 PRIUS (RM778U) Pull the cruise control switch to CANCEL DI–654 DIAGNOSTICS – CRUISE CONTROL SYSTEM CIRCUIT INSPECTION DI7NI–01 DTC P1520 Stop light switch circuit CIRCUIT DESCRIPTION When the brake pedal is depressed, the stop light switch sends a signal to the hybrid vehicle control ECU. When the hybrid vehicle control ECU receives this signal, it cancels the cruise control. A fail–safe function is provided so that the cancel functions normally, even if there is a malfunction in the stop light signal circuit. The cancel condition is that battery voltage is supplied to terminal STP. When the brake is on, battery voltage is normally applied through the STOP fuse and stop light switch to terminal STP of the hybrid vehicle control ECU, and the hybrid vehicle control ECU turns the cruise control OFF. If the harness connected to terminal STP has an open circuit, terminal STP will have battery voltage and the cruise control will be turned OFF. DTC No. P1520 Detection Item Stop light switch circuit. 2001 PRIUS (RM778U) Trouble Area
Stop light switch
Harness or connector between hybrid vehicle control ECU and stop light switch circuit
Hybrid vehicle control ECU DI–655 DIAGNOSTICS – CRUISE CONTROL SYSTEM WIRING DIAGRAM I15 Ignition SW S3 Stop Light SW J/C W–R 7 AM2 IG2 B–W 6 J24 C Instrument Panel J/B 2 2C 1 W–R 2G J25 B B–W ID1 6 2 1B 15A AM2 FL Block No. 1 1 1 F12 F13 2 B–Y H14 ST1– 4 B–W 3 S3 Stop Light SW J/C 1 G–W G–W J14 H14 STP J15 2 1 E D Instrument Panel J/B Engine Room J/B B Hybrid Vehicle Control ECU 9 1J R–B 9 2K 15A STOP 1 2H W FL Block No. 1 B–G B–G 1 100A DC/DC 1 F11 F13 FL Block No. 2 1 120A MAIN F18 Battery I15477 2001 PRIUS (RM778U) DI–656 DIAGNOSTICS – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check operation of stop light. CHECK: Check that stop light comes on when brake pedal is depressed, and turns off when brake pedal is released. NG Check stop light system (See page BE–2). OK 2 Check voltage between terminal STP of hybrid vehicle control ECU connector and body ground. PREPARATION: (a) Remove the hybrid vehicle control ECU with connectors still connected. (b) Turn ignition switch ON. CHECK: Measure voltage between terminal STP of hybrid vehicle control ECU connector and body ground, when the brake pedal is depressed and released. OK: ON (+) (–) Depressed 10 – 14 V Released Below 1 V STP OK I19096 NG 2001 PRIUS (RM778U) Proceed to next circuit inspection shown in problem symptom table (See page DI–648). DI–657 DIAGNOSTICS 3 – CRUISE CONTROL SYSTEM Check voltage between terminal ST1– of hybrid vehicle control ECU connector and body ground. PREPARATION: (a) Remove the hybrid vehicle control ECU with connectors still connected. (b) Turn ignition switch ON. CHECK: Measure voltage between terminal ST1– of hybrid vehicle control ECU connector and body ground, when the brake pedal is depressed and released. OK: ON (+) (–) Depressed Below 1 V Released 10 – 14 V ST1– I19096 OK Proceed to next circuit inspection shown in problem symptoms table (See page DI–648). NG 4 Check wire harness and connector between terminal STP of hybrid vehicle control ECU and stop light switch, and terminal ST1– of hybrid vehicle control ECU and stop light switch (See page IN–41). NG OK Check and replace hybrid vehicle control ECU (See page DI–174 ). 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–659 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI7NJ–01 Power source circuit CIRCUIT DESCRIPTION This circuit provides power to operate the hybrid vehicle control ECU. WIRING DIAGRAM See page DI–156. INSPECTION PROCEDURE 1 Check IGN and EFI fuse. CHECK: Check continuity of IGN and EFI fuse. OK: Continuity NG Replace the failure fuse. OK 2 Check voltage between terminals IGSW, BATT and GND of hybrid vehicle control ECU connector (See page IN–41). PREPARATION: (a) Turn ignition switch OFF. (b) Disconnect the hybrid vehicle control ECU connector. CHECK: Measure voltage between terminals IGSW, BATT and GND OK: Voltage: 10 – 14 V OK NG 2001 PRIUS (RM778U) Proceed to next circuit inspection shown in problem symptoms table (See page DI–648). DI–660 DIAGNOSTICS 3 – CRUISE CONTROL SYSTEM Check wireharness and connector between hybrid vehicle control ECU and body ground (See page IN–41). NG OK Check and repair wireharness and connector between hybrid vehicle control ECU and battery (See page IN–41 ). 2001 PRIUS (RM778U) Repair or replace wireharness or connector. DI–665 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI7NL–01 CRUISE MAIN Indicator Light Circuit CIRCUIT DESCRIPTION When the cruise control main switch is turned ON, CRUISE MAIN indicator light lights up. WIRING DIAGRAM Instrument Panel J/B 6 2B BR W 1 2H 3 W–G 2B B–Y 6 2D 7 2A Combination Meter 14 C10 IG1 Relay 5A AM1 10A GAUGE 5 3 1 2 8 22 L 2A C10 8 W–B 2K I15 Ignition SW IG1 4 2 AM1 B–Y FL Block No. 1 F11 1 100A DC/DC F13 1 B–G IH to Body ECU FL Block No. 2 120A MAIN GR–B CRUISE 2 C11 J11 J/C W–B A F18 1 Battery ID I15479 2001 PRIUS (RM778U) DI–666 DIAGNOSTICS – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check combination meter (See page BE–2). NG OK Check and replace hybrid vehicle control ECU (See page DI–174). 2001 PRIUS (RM778U) Replace combination meter. DI–669 DIAGNOSTICS – COMBINATION METER SYSTEM DI7XP–01 PRE–CHECK 1. BEFORE CHECK Since a trouble symptom may result from multiple causes, check not only the part where a user complains of but also the following items in order to be sure no other trouble is identified.
Fuse related parts
Wire harness related parts
Valve related parts NOTICE:
Setting the ignition switch to START temporarily stops all meter operation, however, this is not an error.
When replacing the combination meter ECU, carefully avoid any contact with the IC.
Removing a battery terminal during engine operation may cause a reversed current and lead to malfunction.
When disconnecting any connector or terminal, be sure to disconnect the battery terminal. 2001 PRIUS (RM778U) DI–670 DIAGNOSTICS – COMBINATION METER SYSTEM 2. FUEL GAUGE DIAGNOSIS CHECK (a) Fuel emergency display HINT: If FR voltage input to the fuel sender gauge is abnormal (4.8 V or more, or 0.06 V or less) due to any error, an emergency will be displayed. (b) Display: Immediately after the ignition switch is ON, all of the segments flash. Diagnosis display Trouble Item Plausible Cause All segments flashing (Flashing pattern No. 1) Cycle: 1.2 sec Duty: 50 % Multiple communication error Communication is cut off. 4. Body ECU faulty 5. Engine ECU faulty 6. Open or short in wire harness for communication HINT: Referring to the attached reference material 1 or 2, specify the main cause All segments flashing (Flashing pattern No. 2) (300 msec. ON, 300 msec OFF) x 2 + 1.2 sec. OFF Sender gauge related trouble 1. Sender gauge faulty 2. Open or short in wire harness Display segments and ”E” flashing. (Flashing pattern No. 1) Cycle: 1.2 sec Duty: 50 % Temperature sensor (located in the tank) related trouble 1. Temperature sensor faulty 2. Open or short in wire harness Display segments and ”E” flashing. (Flashing pattern No. 2) (300 msec. ON, 300 msec. OFF) x 2 + 1.2 sec. OFF Indication sensor (located in the meter ) trouble 1. Combination meter faulty Segment No. 1 flashing (Flashing pattern No. 1) Cycle: 1.2 sec Duty: 50 % This does not mean any failure. When a battery is connected, it continues flashing until the volume is confirmed. This occurs when the battery is turned ON. HINT: Low fuel warning: Cycle: 0.6 sec.; Duty: 50 % Flashing pattern No.1 ON OFF 0.6 sec. 0.6 sec. Flashing pattern No.2 ON OFF 0.3 sec. 0.3 sec. 1.2 sec. 0.3 sec. 2001 PRIUS (RM778U) DI–672 DIAGNOSTICS – COMBINATION METER SYSTEM DI7XR–01 TERMINALS OF ECU Disconnect connector ”A” and ”B” from the combination meter and inspect the connectors on the wire harness side as shown in the table. COMBINATION METER Connector ”A” Connector ”B” (LHD model) I17803 Tester connection Condition Specified condition A1 – Ground (ILL – Body ground) Ignition switch ON and tail cancel switch ON or OFF Below 1V or 4.5 – 5.5 V A2 – Ground (E – Body ground) Constant Continuity A3 – Ground (OPO – Body ground) Ignition switch ON and trip reset switch ON or OFF Below 1V or 4.5 – 5.5 V A9 – Ground (SI – Body ground) Ignition switch ON and slowly turn drive wheel Below 1V or 10 – 14 V A10 – Ground (LP – Body ground) Ignition switch ON and ABS indicator ON or OFF Below 1V or 10 – 14 V A11 – Ground (L – Body ground) Ignition switch ON Pulse generation A13 – Ground (+S – Body ground) I iti switch Ignition it h ON and d slowly l l turn t drive d i wheel h l A14 – Ground (ES – Body ground) Constant Continuity A15 – Ground (EP – Body ground) Constant Continuity A16 – Ground (SW – Body ground) Ignition switch ON and air bag indicator light ON or OFF Below 1V or 10 – 14 V A17 – Ground (S – Body ground) Headlight dimmer switch Hi or Low Below 1V or 10 – 14 V A18 – Ground (B – Body ground) Ignition switch ON and turn signal switch right Below 1V or 10 – 14 V A19 – Ground (B – Body ground) Ignition switch ON and turn signal switch left Below 1V or 10 – 14 V A21 – Ground (B – Body ground) Constant 10 – 14 V A22 – Ground (IG – Body ground) Ignition switch OFF or ON Below 1V or 10 – 14 V 2001 PRIUS (RM778U) Below 1V or 10 – 14 V Below 1V or 4.5 – 5.5 V DI–673 DIAGNOSTICS – COMBINATION METER SYSTEM B1 – Ground (ROUT – Body ground) Ignition switch ON and shift lever position is ”R” or except ”R” Below 1V or 10 – 14 V B2 – Ground (MPX+ – Body ground) Ignition switch ON Pulse generation B3 – Ground (MPX – Body ground) Ignition switch ON Pulse generation B5 – Ground (ACC – Body ground) Ignition switch ACC 10 – 14 V 2001 PRIUS (RM778U) DI–674 DIAGNOSTICS – COMBINATION METER SYSTEM DI7XS–01 PROBLEM SYMPTOMS TABLE TROUBLESHOOTING: Flow chart No. Symptom See page 1 Check the communication between the combination meter and the multiplex communication circuit. DI–671 2 The whole meter does not function DI–672 3 The margin of error in speedometer is large. Or it remains as 0 mph. DI–673 4 Fuel receiver gauge is inoperative or improper. DI–674 5 Indicators or warning lights do not light up. DI–676 Fuel gauge: Symptom Displayed level is higher or lower than the actual level. Suspect Area See page 1. Inclination sensor resetting 2. Body ECU BE–47 IN–41 General: Symptom Suspect area Meter display does not properly function. 3. Combination meter ECU Entirely black screen appears. 1. Fuse 2. Wire harness and connector 3. Combination meter ECU Turning the light control switch ON does not dim the light. 1. Illumination switch 2. Wire harness and connector 3. Combination meter ECU Brightness cannot be changed by the illumination switch operation. 1. Illumination switch 2. Wire harness and connector 3. Combination meter ECU Speedometer: Symptom Suspect area Improper display (Remained as 0 km/h) 1. 2. 3. 4. Accessory that utilizes vehicle speed signals Brake ECU Combination meter ECU Wire harness and connector Speedometer only does not light up. 1. Combination meter ECU Abnormal display (Incomplete numbers displayed) 1. Combination meter ECU DIsplayed value changes frequently or sharply. 1. 2. 3. 4. Accessory that utilizes vehicle speed signals Brake ECU Combination meter ECU Wire harness and connector Margin of error in speedometer is large. 1. 2. 3. 4. Accessory that utilizes vehicle speed signals Brake ECU Combination meter ECU Wire harness and connector ODO/TRIP Meter: Symptom Suspect area ODO/TRIP only does not light up. 1. Combination meter ECU Abnormal display (Incomplete number displayed) 1. Combination meter ECU Both meters do not integrate values. (When speedometer is normal) 1. Combination meter ECU Trip meter only does not integrate values. 1. ODO/TRIP switch 2. Combination meter ECU 2001 PRIUS (RM778U) DI–675 DIAGNOSTICS – COMBINATION METER SYSTEM Trip meter cannot be reset. 1. ODO/TRIP switch 2. Combination meter ECU Display cannot be shifted among ODO, TRIPA and TRIPB. 1. ODO/TRIP switch 2. Combination meter ECU Without resetting, the display returns to 0.0 km. 1. ODO/TRIP switch 2. +B wire harness 3. Combination meter ECU Error of accumulated distance is large. 1. 2. 3. 4. 5. Accessory that utilizes vehicle speed signals. GND wire harness Brake ECU Wire harness and connector Combination meter ECU Others: Symptom Suspect area Some indicators or warning lights are always ON. 1. 2. 3. 4. Meter circuit plate Corresponding switch and ECU Combination meter ECU Multiplex communication circuit Some indicators or warning lights do not light up. 1. 2. 3. 4. 5. Bulb Meter circuit plate Corresponding switch and ECU Combination meter ECU Multiplex communication circuit Buzzer does not stop. 1. Combination meter ECU 2. Corresponding switch and ECU 2001 PRIUS (RM778U) DI–681 DIAGNOSTICS – COMBINATION METER SYSTEM DI7XX–01 5. Indicators or warning lights do not light up. (*multiplex communication circuit input indicator or warning) INSPECTION PROCEDURE 1 Multiplex communication circuit input indicator or warning. 2 Communication check. CHECK: Check if the communication between the combination meter and the multiplex communication circuit is normal or not. Yes No 3 Communication error. Wire harness faulty. Check the bulb or circuit plate. CHECK: Check if the bulb circuit plate is normal or not. Check open or short circuit in wire harness. Yes No 2001 PRIUS (RM778U) Bulb or circuit plate faulty. DI–682 DIAGNOSTICS 4 – COMBINATION METER SYSTEM Check the corresponding switch or ECU. CHECK: Check if the corresponding switch or ECU is normal or not. Yes No Corresponding switch or ECU faulty. Combination meter ECU faulty. *: Multiplex communication input Single Communication Input OPEN DOOR WARNING HI–BEAM INDICATOR BRAKE WARNING TURN SIGNAL IND OUTPUT CONTROL INDICATOR SRS WARNING SHIFT POSITION INDICATOR ABS WARNING SEAT BELT WARNING CHECK ENGINE WARNING READY INDICATOR WATER TEMPERATURE WARNING OIL PRESSURE WARNING CRUISE CONTROL INDICATOR TAIL INDICATOR DISCHARGE WARNING 2001 PRIUS (RM778U) DI–686 DIAGNOSTICS – BODY CONTROL SYSTEM DI7NN–01 TERMINALS OF ECU BODY ECU B8 B9 I15530 Symbols (Terminals No.) Wiring Color FLD ↔ E (B8–2 – B9–1) G−B↔W–B FLU ↔ E (B8–3 – B9–1) R–W↔W–B LUG ↔ E (B8–5 – B9–1) RX (B8–6) L – B ↔ W−B W B Y Condition STD Voltage (V) Power window (FR LH) is not operating Below 1 v Power window (FR LH) is operating downward 10 – 14 v Power window (FR LH) is not operating Below 1 v Power window (FR LH) is operating upward 10 – 14 v Luggage compartment door key lock and unlock switch is ON Below 1 v Luggage compartment door key lock and unlock switch is OFF 10 – 14 v AVC – LAN communication circuit –– PRG (B8–7) B–R Wireless door lock ECU communication circuit –– RDA (B8–8) L Wireless door lock ECU communication circuit –– HR ↔ E (B8–10 − B9–1) BDR – – Body ground (B8–11 − Body ground) B – R ↔ W− W B W–L↔ Body ground PCTY ↔ E (B8–12 − B9–1) R–W↔W−B HCTY ↔ E (B8–13 − B9–1) R–W↔W−B LCTY ↔ E (B8–14 − B9–1) R–L↔W−B Horn switch is ON Below 1 v Horn switch is OFF 10 – 14 v Constant 10 – 14 v Passenger door courtesy switch is OFF Below 1 v Passenger door courtesy switch is ON 10 – 14 v Engine hood courtesy switch is OFF Below 1 v Engine hood courtesy switch is ON 10 – 14 v Luggage door courtesy switch is OFF Below 1 v Luggage door courtesy switch is ON 10 – 14 v MPX+ (B8–15) GR – B Multiplex communication circuit –– MPX– (B8–16) GR Multiplex communication circuit –– LSWP ↔ E (B8–17 − B9–1) W↔W−B LSR ↔ E (B8–18 − B9–1) W–L↔W−B SH ↔ E (B8–20 − B9–1) B–W↔W−B E – Body ground (B9–1 − Body ground) 2001 PRIUS (RM778U) W–B↔ Body ground Passenger door unlock detection switch OFF (door unlocked) Below 1 v Passenger door unlock detection switch ON (door locked) 10 – 14 v Rear door unlock detection switch OFF (door unlocked) Below 1 v Rear door unlock detection switch ON (door locked) 10 – 14 v Theft deterrent system is not operating Below 1 v Theft deterrent system is operating 10 – 14 v Constant Below 1 v DI–687 DIAGNOSTICS Symbols (Terminals No.) BODY CONTROL SYSTEM Wiring Color HRLY ↔ E (B9–2 − B9–1) R–W↔W−B PKBL ↔ E (B9–3 − B9–1) P–L↔W−B DKBL ↔ E (B9–5 − B9–1) G–O↔W−B L2 ↔ E (B9–7 − B9–1) G↔W−B B ↔ Body ground (B9––9 − Body ground) R–G↔ Body ground ACTD ↔ E (B9–10 − B9–1) R↔W−B TRLY ↔ E (B9–11 − B9–1) LG ↔ W − B IND ↔ E (B9–13 − B9–1) LG – B ↔ W−B L1 ↔ E (B9–14 − B9–1) G–B↔W−B UL1 ↔ E (B9–15 − B9–1) R–B↔W−B UL2 ↔ E (B9–16 − B9–1) L–B↔W−B H↔E (B9–17 − B9–1) R↔W−B T↔E (B9–18 − B9–1) LG –B B↔W–B 2001 PRIUS (RM778U) – Condition STD Voltage (V) Light control switch OFF Below 1 v Light control switch TAIL or HEAD 10 – 14 v Passenger side buckle switch ON (belt fastened) Below 1 v Passenger side buckle switch OFF (belt fastened) 10 – 14 v Driver side buckle switch ON (belt fastened) Below 1 v Driver side buckle switch OFF (belt fastened) 10 – 14 v Door lock manual switch OFF or UNLOCK Below 1 v Door lock manual switch LOCK 10 – 14 v Constant 10 – 14 v Driver door is operating 10 – 14 v Light control switch OFF Below 1 v Light control switch TAIL or HEAD 10 – 14 v During set is theft deterrent system 10 – 14 v Door key lock and unlock switch OFF or UNLOCK Below 1 v Door key lock and unlock switch LOCK 10 – 14 v Door key lock and unlock switch OFF or LOCK Below 1 v Door key lock and unlock switch UNLOCK 10 – 14 v Door lock manual switch OFF or LOCK Below 1 v Door lock manual switch UNLOCK 10 – 14 v Light control switch OFF or TAIL Below 1 v Light control switch HEAD 10 – 14 v Light control switch OFF Below 1 v Light control switch TAIL or HEAD 10 – 14 v DI–688 DIAGNOSTICS – BODY CONTROL SYSTEM DI62G–07 PROBLEM SYMPTOMS TABLE POWER WINDOW CONTROL SYSTEM Symptom Suspect Area See page All the power windows does not operate. 3. Master switch circuit 4. Driver door ECU with master switch 5. Body ECU DI–724 DI–730 IN–41 Power window does not operate. 1. Power window switch circuit 2. Body ECU DI–726 IN–41 DOOR LOCK CONTROL Symptom Suspect Area See page Lock or unlock cannot be operated with door lock control S/W. 1. Door lock control switch circuit (Master switch) 2. Body ECU DI–706 DI–724 IN–41 Door key linked function does not operate. 1. Door key lock and unlock switch circuit 2. Body ECU DI–708 IN–41 Key confinement prevention function does not operate. 1. Key unlock switch circuit 2. Body ECU DI–695 IN–41 Does not lock and unlock each door only. 1. Door lock motor circuit 2. Body ECU DI–712 IN–41 Luggage compartment door opener function does not operate. 1. Luggage component door courtesy switch circuit 2. Body ECU DI–722 IN–41 WIRELESS DOOR LOCK CONTROL Symptom Suspect Area Transmitter Wireless tuner circuit Key unlock warning switch circuit Body ECU See page All function of wireless door lock control system do not operate. 1. 2. 3. 4. BE–83 DI–728 DI–695 IN–41 Lock (or unlock) function does not operate. 1. Door key lock and unlock switch circuit 2. Door unlock detection switch circuit 3. Body ECU DI–708 DI–710 IN–41 Automatic lock function operates even if any door is opened within 30 seconds after all doors are unlocked by wireless door lock control system . 1. Door courtesy switch circuit 2. Body ECU DI–714 IN–41 ILLUMINATED ENTRY Symptom Illuminated entry does not operate. Suspect Area 1. Driver door courtesy switch circuit 2. Illuminaction circuit 3. Body ECU See page DI–714 DI–702 IN–41 HEADLIGHT AND TAILLIGHT SYSTEM: Symptom Suspect Area See page Headlight does not light up. 1. Light control switch circuit 2. Headlight control relay circuit 3. Body ECU DI–689 DI–693 IN–41 Taillight does not light up. 1. Light control switch circuit 2. Taillight control relay circuit 3. Body ECU DI–689 DI–691 IN–41 Auto turn–off system does not operate. 1. Driver door courtesy switch circuit 2. Body ECU DI–714 IN–41 2001 PRIUS (RM778U) DI–689 DIAGNOSTICS – BODY CONTROL SYSTEM OTHERS Symptom Suspect Area See page Does not turn off the driver seat belt warning light 1. Driver buckle switch circuit 2. Body ECU DI–716 IN–41 Does not turn off the passenger seat belt warning light. 1. Passenger buckle switch circuit 2. Body ECU DI–718 IN–41 Theft deterrent indicator light does not blink when system is set. 1. Indicator light circuit 2. Body ECU DI–704 IN–41 1. Power source circuit 2. Body ECU DI–685 IN–41 Body ECU does not operate. 2001 PRIUS (RM778U) DI–690 DIAGNOSTICS – BODY CONTROL SYSTEM DI6QW–04 CIRCUIT INSPECTION Power Source Circuit CIRCUIT DESCRIPTION This circuit provides power to operate the Body ECU. WIRING DIAGRAM J27 J/C Instrument Panel J/B 7.5A ECU–B 5 2C 7.5A OBDII W 1 2H W–G 3 2B F R–G F R–G 9 W–L 2D 5 IG1 Relay 10A GAUGE 3 15 8 2D 6 2D 1 B9 W–B 8 2K 2 1 B 11 D W–L B8 BDR J26 J/C 8 B D 30A DOOR 5A AM1 Body ECU 9 B9 IG E W–B I15 Ignition Switch W–G 2 AM1 IG1 B–Y 4 A F18 FL Block No. 2 FL Block No. 1 W 1 F11 100A DC/DC 1 F13 J11 J/C 120A MAIN B–G Battery ID I15489 2001 PRIUS (RM778U) DI–691 DIAGNOSTICS – BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check ECU–B, DC/DC, GAUGE and DOOR fuse. CHECK: Check continuity of ECU–B, DC/DC, GAUGE and DOOR fuse. OK: Continuity NG Replace the failure fuse. OK 2 Check voltage between terminals B, BDR and E of body ECU connector. PREPARATION: (a) Turn ignition switch OFF. (b) Disconnect the Body ECU connector. CHECK: Measure voltage between terminals B, BDR and E. OK: Voltage: 10 – 14V OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–683). NG 3 Check wireharness and connector between body ECU and body ground (See page IN–41). NG OK Check and repair wireharness and connector between Body ECU and battery. 2001 PRIUS (RM778U) Repair or replace wireharness or connector. DI–692 DIAGNOSTICS – BODY CONTROL SYSTEM DI7NO–01 Ignition Switch Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is turned to the ACC position, battery voltage is applied to the terminal ACC of the ECU and when the ignition switch is turned to the ON position, battery voltage is applied to the terminal IG of the ECU. WIRING DIAGRAM J27 J/C Instrument Panel J/B 7.5A ECU–B 5 2C 7.5A OBDII W 1 2H W–G 3 2B Body ECU F R–G F R–G 9 W–L 2D IG1 Relay 10A GAUGE 5 3 15 8 2D 6 2D 1 B9 W–B 8 2K 2 1 B 11 D W–L B8 BDR J26 J/C 8 B D 30A DOOR 5A AM1 9 B9 IG E W–B I15 Ignition Switch W–G 2 AM1 IG1 B–Y 4 A F18 FL Block No. 2 FL Block No. 1 W 1 F11 100A DC/DC 1 F13 J11 J/C 120A MAIN B–G Battery ID I15489 2001 PRIUS (RM778U) DI–693 DIAGNOSTICS – BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check AM1 fuse. CHECK: Check continuity of AM1 fuse. OK: Continuity NG Replace the failure fuse. OK 2 Check voltage between terminals 8, 15 and E of body ECU connector. PREPARATION: Turn ignition switch ON. CHECK: Measure voltage between terminals 8, 15 and E. OK: Voltage: 10 – 14V OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–683). NG 3 Check wireharness and connector between body ECU and body ground (See page IN–41). NG OK Check and repair wireharness and connector between body ECU and battery. 2001 PRIUS (RM778U) Repair or replace wireharness or connector. DI–694 DIAGNOSTICS – BODY CONTROL SYSTEM DI5VO–07 Light Control Switch Circuit CIRCUIT DESCRIPTION This circuit defects the state of the light control switch. WIRING DIAGRAM B9 BODY ECU 6 ID2 LG–R 5 ID2 R C13 Combination SW 14 T J17 J/C A Light Control SW 18 LG–R 17 R T H 13 H EL HF HU HL OFF TAIL HEAD LOW Dimmer SW HIGH FLASH 16 IG W–B I15486 2001 PRIUS (RM778U) DI–695 DIAGNOSTICS – BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check light control switch (See page DI–689). NG Replace the headlight control switch. OK 2 Check wireharness and connector between headlight control switch and body ECU (See page IN–41). NG OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–683). 2001 PRIUS (RM778U) Repair or replace wireharness or connector. DI–696 DIAGNOSTICS – BODY CONTROL SYSTEM DI6QY–04 Taillight Relay Circuit CIRCUIT DESCRIPTION Taillight relay will be ”ON” by operating the taillight switch. The transistor which activates the tail light relay has two sorts: one activates by the tail light switch for fail safe and the other activates by CPU. When the theft deterrent system is activated, it causes the transistor in the ECU to switch ON and OFF at approximately 0.4 sec. intervals. This switches the taillight control relay ON and OFF, thus flashing the taillights (See the wiring diagram below). In this condition, if any of the following operations is done, the transistor in the ECU goes OFF and the taillight control relay switches OFF, thus stopping the taillights flashing: (1) Unlock the front LH or RH door with a key. (2) Turn the ignition switch to ACC or ON position. (3) Unlock the doors with the wireless door lock control system. (4) Wait for approximately 60 seconds. WIRING DIAGRAM B9 BODY ECU to Taillight Instrument Panel J/B TAIL RELAY 1 2H 7.5A TAIL 5 3 5 2F 1 2 6 2K 1 F11 100A DC/DC 11 LG TRLY F18 FL BLock No. 2 FL Block No. 1 W LG 2 ID2 1 B–G F13 1 120A MAIN Battery I15485 2001 PRIUS (RM778U) DI–697 DIAGNOSTICS – BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check taillight relay (See page DI–691). NG Replace the taillight relay. OK 2 Check wireharness and connector between taillight relay and body ECU, battery and taillight relay (See page IN–41). NG OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–683). 2001 PRIUS (RM778U) Repair or replace wireharness or connector. DI–698 DIAGNOSTICS – BODY CONTROL SYSTEM DI5VQ–04 Headlight Relay Circuit CIRCUIT DESCRIPTION Head light relay will be ”ON” by operating the headlight switch. The transistor which activates the headlight relay has two sorts: one activates directly by the headlight switch for fail safe and the other activates by CPU. the one that activates by CPU has two systems and prevents the headlight from turning off at the time of one system trouble in the automatic operation circuit. When the theft deterrent system is activated, it causes the transistor in the ECU to switch ON and OFF at approximately 0.25 sec. intervals. This switches the headlight control relay ON and OFF, thus flashing the headlights (See the wiring diagram below). In this condition, if any of the following operations is done, the transistor in the ECU goes OFF and the headlight control relay switches OFF, thus stopping the headlights flashing: (1) Unlock the front LH or RH door with a key. (2) Turn the ignition switch to ACC or ON position. (3) Unlock the doors with the wireless door lock control system. (4) Wait for approximately 60 seconds. WIRING DIAGRAM B9 Body ECU Engine Room J/B HEAD Relay Short Pin 2 4 1 7 1F 10A HEAD (RH) 1 10A HEAD (LH) 1 1B Short Pin 1 2 4 R–L H1 Headlight LH 6 1F 3 1 8 1F 3 R–G B FL Block No. 1 1 1 F12 F13 R–W F18 FL Block No. 2 120A MAIN 6 IA2 J20 J/C R–W E 3 H2 Headlight RH 3 1 R–W ID2 E D J13 R–G 7 2I Battery Instrument Panel J/B 10 2A 2 HRLY R–G B–G 1 R–W F J12 3 IA1 R–G C10 High Beam Indicator Light (Comb. meter) L L 15 17 8 2A E J4 R–G 8 2K E J4 E J5 J11 J/C W–B A ID Instrument Panel J/B I15484 2001 PRIUS (RM778U) DI–699 DIAGNOSTICS – BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check headlight relay (See page DI–693). NG Replace the headlight relay. OK 2 Check wireharness and connector between headlight relay and body ECU, battery and headlight relay (See page IN–41). NG OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–683). 2001 PRIUS (RM778U) Repair or replace wireharness or connector. DI–700 DIAGNOSTICS – BODY CONTROL SYSTEM DI7NP–01 Key unlock warning switch circuit CIRCUIT DESCRIPTION The key unlock warning switch goes on when the ignition key is inserted in the key cylinder and goes off when the ignition key is removed. The ECU operates the key confinement prevention function while the key unlock warning switch is on. WIRING DIAGRAM Body ECU Instrument Panel J/B J11 J/C A W–B 8 2K 8 2D U1 Key Unlock Warning Switch 2 1 W–B A J25 W–B L–B B J27 J/C A J24 Instrument Panel J/B B J27 L–B 9 2C 12 KSW ID I17121 INSPECTION PROCEDURE 1 Check key unlock warning switch (See page BE–62). NG Replace the key unlock warning switch. OK 2 Check wireharness and connector between key unlock warning switch and body ECU. NG 2001 PRIUS (RM778U) Repair or replace wireharness or connector. DI–701 DIAGNOSTICS OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–683). 2001 PRIUS (RM778U) – BODY CONTROL SYSTEM DI–702 DIAGNOSTICS – BODY CONTROL SYSTEM DI2A3–06 Horn Circuit CIRCUIT DESCRIPTION The horn is connected to the body ECU and activated by the body ECU. WIRING DIAGRAM Engine Room J/B BODY ECU Horn Relay 2 1B 10A HORN 5 3 1 2 9 1F B–R 10 B8 HR 4 ID2 2 1J D B–R FL Block No. 1 1 1 F12 F13 B J20 J/C B–G D B–R B–W F18 FL Block No. 2 120A MAIN B–R C14 Horn SW (Comb. SW) 1 1 Battery 8 B–R IA2 6 H4 Horn I15492 2001 PRIUS (RM778U) DI–703 DIAGNOSTICS – BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check horn (See page DI–697). NG Replace the horn. OK 2 Check wireharness and connector between horn relay and body ECU, battery and horn relay (See page IN–41). NG OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–683). 2001 PRIUS (RM778U) Repair or replace wireharness or connector. DI–704 DIAGNOSTICS – BODY CONTROL SYSTEM DI7NQ–01 Theft Deterrent Horn Circuit CIRCUIT DESCRIPTION When the theft deterrent system is activated, the relay in the ECU turns ON and OFF cycles of approximately 0.2 sec., causing the theft deterrent horn to blow (See the wiring diagram below). In this condition, if any of the following operations is done, the relay in the ECU turns OFF, thus stopping the theft deterrent horn from blowing: (1) Unlock the front LH or RH door with key. (2) Turn the ignition switch to ACC or ON position. (3) Unlock the doors with the wireless door lock control system. (4) Wait for approximately 60 seconds. (5) Push the panic switch of the wireless door lock control system. Except for the anti–theft purpose, the theft deferrent horn is used as a high–pitched horn. WIRING DIAGRAM Body ECU B–W 9 IE1 20 B–W B8 SH 1 T1 Theft Deterrent Horn I15493 2001 PRIUS (RM778U) DI–705 DIAGNOSTICS – BODY CONTROL SYSTEM INSPECTION PROCEDURE HINT: The flow chart below is based on the premise that the horns blow normally whenever the horn switch is operated. If horn operation is not normal when the horn switch is operated, check the horn switch. 1 Check voltage between terminal 1 of theft deterrent horn connector and body ground. (–) PREPARATION: Remove the theft deterrent horn and disconnect the connector. CHECK: Measure voltage between terminal 1 of theft deterrent horn connector and body ground. OK: Voltage: 10 – 14 V (+) 1 I11582 NG Check and repair harness and connector between HORN fuse and theft deterrent horn. OK 2 Check theft deterrent horn. CHECK: Connect positive (+) lead to terminal 1 and negative (–) lead to ground to theft deterrent horn connector. OK: Theft deterrent horn blows. (–) 1 (+) I11583 NG OK 2001 PRIUS (RM778U) Replace theft deterrent horn. DI–706 DIAGNOSTICS 3 – BODY CONTROL SYSTEM Check harness and connector between body ECU and theft deterrent horn (See page IN–41). NG OK Check and replace body ECU. 2001 PRIUS (RM778U) Check and repair harness or connector. DI–707 DIAGNOSTICS – BODY CONTROL SYSTEM DI6LX–03 Illumination circuit CIRCUIT DESCRIPTION Receiving the courtesy signal from either of the door ECU, the Body ECU will make the interior light, ignition light, and foot light come on. WIRING DIAGRAM Body ECU J/C D J30 E D J29 J30 L–Y L–Y I16 Interior Light E J29 2 L5 Luggage Compartment Light 1 2N 1 L–Y 7 R–B P4 Front Personal Light 1 2 L–Y W–B Engine Room J/B Instrument Panel J/B 3 2M Instrument Panel J/B 2 2G 15A DOME 7 1J L–Y F18 Fusible Link Block No.2 120A MAIN FL B J/C 1 2 1B 1 F13 F12 J/C 1 B L6 Luggage Compartment Light SW Battery B W–B BI I15508 2001 PRIUS (RM778U) DI–708 DIAGNOSTICS – BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check illumination light (Interior light system)(See page BE–27). NG Replace the failure light. OK 2 Check wireharness and connector between each illumination light and Body ECU, battery and each illumination light (See page IN–41). NG OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–683). 2001 PRIUS (RM778U) Repair or replace wireharness or connector. DI–709 DIAGNOSTICS – BODY CONTROL SYSTEM DI7NY–01 Indicator Light Circuit CIRCUIT DESCRIPTION When the theft deterrent system is preparing to set, this circuit lights up the indicator light. When the system has been set, it continuously turns the indicator light on for 0.2 secs. and turns it off for 1.8 secs., thus blinking the indicator light. WIRING DIAGRAM Body ECU C7 Center Cluster SW (Center Cluster Module Control) J27 J/C 6 A LG–B A LG–B 13 B9 IND I15496 2001 PRIUS (RM778U) DI–710 DIAGNOSTICS – BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check indicator light. (center cluster module control) NG Replace center cluster module control. OK 2 Check harness and connector between body ECU and indicator light, indicator light and body ground (See page IN–41). NG Repair or replace harness or connector. OK Check and replace body ECU.*1 *1: When there is a malfunction that the theft deterrent system cannot be set, proceed to the next numbered circuit inspection shown on problem symptom table (See page DI–683). 2001 PRIUS (RM778U) DI–711 DIAGNOSTICS – BODY CONTROL SYSTEM DI2EY–04 Door lock control switch circuit CIRCUIT DESCRIPTION Door lock control switch circuit can be checked using DTC check. (Refer to DI–765) WIRING DIAGRAM Body ECU D10 Door Lock Control SW Front RH LOCK W–B 2 IQ1 G–B 3 W–B 5 UNLOCK W–B A J19 6 A J18 R–B 1 IN1 6 IN1 G–B R–B 14 B9 L1 15 B9 UL1 J17 J/C A A W–B IG I15481 2001 PRIUS (RM778U) DI–712 DIAGNOSTICS – BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check the door lock control switch (See page BE–62). NG Replace the door lock control switch. OK 2 Check wireharness and connector between door lock control switch and body ECU. NG OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–683). 2001 PRIUS (RM778U) Repair or replace wireharness or connector. DI–713 DIAGNOSTICS – BODY CONTROL SYSTEM DI6R6–04 Door Key Lock and Unlock Switch Circuit CIRCUIT DESCRIPTION The door key lock and unlock switch is built in the door key cylinder. When the key is turned to the lock side, terminal 3 of the switch is grounded and when the key is turned to the unlock side, terminal 2 of the switch is grounded. WIRING DIAGRAM Body ECU D14 Door Key Lock and Unlock Switch UNLOCK W–B 7 BB1 1 L–B 4 W–B 2 G LOCK A J19 A J18 11 IN1 L–B 12 IN1 G 16 B9 UL2 7 B9 L2 J17 J/C A W–B IG I15482 2001 PRIUS (RM778U) DI–714 DIAGNOSTICS – BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check the door key lock and unlock switch (See page DI–708). NG Replace the door key lock and unlock switch. NG 2 Check wireharness and connector between door key lock and unlock switch and body ECU (See page IN–41). NG OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–683). 2001 PRIUS (RM778U) Repair or replace wireharness or connector. DI–715 DIAGNOSTICS – BODY CONTROL SYSTEM DI7NT–01 Door unlock detection switch CIRCUIT DESCRIPTION The door unlock detection switch is built in the door lock motor assembly. This switch is ON when the door lock knob is in the unlock position and OFF when the lock knob is in the lock position. The ECU detects the door lock knob conditions is this circuit. It is used as one of the operating conditions for the key confinement prevention function. WIRING DIAGRAM A J18 J/C W–B A J17 J/C A W–B 1 BB1 D14 Door Unlock Detection Switch Front RH A J19 W–B 7 BB1 4 IG 3 W W–B D12 Door Unlock Detection Switch Rear RH 7 1 2 BB1 W–B W–L D11 Door Unlock Detection Switch Rear LH 7 3 4 BA1 W–L W–L W–B 1 BA1 Body ECU W–L 2 IN1 12 ID2 B 1 J23 IF1 W–L W 17 B8 LSWP W–L B J22 W–B B J22 BI W–L 18 B8 LSR J/C I15480 2001 PRIUS (RM778U) DI–716 DIAGNOSTICS – BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check door unlock detection switch (See page DI–710). NG Replace the door lock motor. OK 2 Check wireharness and connector between door unlock detection switch and body ECU. NG OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–683). 2001 PRIUS (RM778U) Repair or replace wireharness or connector. DI–717 DIAGNOSTICS – BODY CONTROL SYSTEM DI7NS–01 Door lock motor circuit WIRING DIAGRAM Body ECU D13 Door Lock Motor Front LH 1 R 2 G 7 IG1 10 B9 ACTD R 5 IC1 G C J14 D14 Door Lock Motor Front RH G 5 IQ1 R 6 IQ1 G 2 BB1 R 6 BB1 6 5 D12 Door Lock Motor Rear RH 4 3 D11 Door Lock Motor Rear LH 2 G 1 R 2 BA1 6 BA1 G R A J15 C J14 B J15 B J14 G A J15 R B J15 G R G R 4 2I 9 1 2J 16 ACT+ ACT– 8 2L 9 2L Instrument Panel J/B I15483 2001 PRIUS (RM778U) DI–718 DIAGNOSTICS – BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check door lock motor (See page BE–62). NG Replace the door lock motor. OK 2 Check wireharness and connector between door lock motor and body ECU. NG OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–683). 2001 PRIUS (RM778U) Repair or replace wireharness or connector. DI–719 DIAGNOSTICS – BODY CONTROL SYSTEM DI7NU–01 Door Courtesy Switch Circuit CIRCUIT DESCRIPTION The door courtesy switch goes on when the door is opened and goes off when door is closed. WIRING DIAGRAM 13 ID2 R–W R–W Instrument Panel J/B J16 A J/C R–W A D J/C F J12 J13 R–W 1 2K 3 R–G 6 2L 6 R–W 3 IB1 R R–W 1 D7 Door Courtesy SW Front RH Body ECU 12 B8 PCTY 1 D6 Door Courtesy SW Front LH 1 D8 Door Courtesy SW Rear LH 1 DCTY RCTY 3 2K D9 Door Courtesy SW Rear RH I15490 2001 PRIUS (RM778U) DI–720 DIAGNOSTICS – BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check courtesy switch (See page BE–27). NG Replace the courtesy switch. OK 2 Check that there is a grounding malfunction caused by looseness of the tighten screw. NG Install screw. OK 3 Check wireharness and connector between courtesy switch and body ECU (See page IN–41). NG OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–683). 2001 PRIUS (RM778U) Repair or replace wireharness or connector. DI–721 DIAGNOSTICS – BODY CONTROL SYSTEM DI6R2–04 Driver Buckle Switch Circuit CIRCUIT DESCRIPTION When the buckle switch of the driver’s seat is ON with the ignition switch ON, the body ECU sends a signal to make the seat belt warning light for the driver’s seat light up and to sound a buzzer. When the buckle switch of the passenger seat is ON and the passenger seat belt occupant detecting sensor is ON with the ignition switch ON, the body ECU sends a signal to make the seat belt warning light for the passenger seat light up. WIRING DIAGRAM Body ECU B20 Buckle SW LH 1 W–B J29 J/C A A 11 IJ1 W–B D J23 8 IJ1 G–O G–O 2 E J22 W–B A J24 J/C G–O A J24 5 B9 DBKL W–B Instrument Panel J/B J11 J/C A W–B 8 2K 8 2D W–B ID I15488 2001 PRIUS (RM778U) DI–722 DIAGNOSTICS – BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check buckle switch (See page DI–716). NG Replace the buckle switch. OK 2 Check wire harness and connector between buckle switch and body ground (See page IN–41). NG OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–683). 2001 PRIUS (RM778U) Repair or replace wire harness or connector. DI–723 DIAGNOSTICS – BODY CONTROL SYSTEM DI7NR–01 Passenger buckle switch and seat belt warning occupant detection sensor CIRCUIT DESCRIPTION This circuit detects the conditions of the passenger buckle switch and the seat belt warning occupant detection sensor, and makes the passenger seat belt warning flash. WIRING DIAGRAM Body ECU B21 Buckle SW RH and Seat Belt Warning Occupant Detection SW 9 IJ1 3 1 P–L W–B 10 IJ1 A J25 W–B J/C P–L A J24 W–B 8 2D W–B 3 B9 PBKL Instrument Panel J/B J11 J/C W–B A 8 2K ID I15487 2001 PRIUS (RM778U) DI–724 DIAGNOSTICS – BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check passenger buckle switch (See page DI–718). NG Replace the passenger buckle switch. OK 2 Check seat belt warning occupant detection sensor (See page BE–42). NG Replace the seat belt warning occupant detection sensor. OK 3 Check wireharness and connector between seat belt warning occupant detection sensor and body ECU, passenger buckle switch and seat belt warning occupant detection sensor, passenger buckle switch and body ground. NG OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–683). 2001 PRIUS (RM778U) Repair or replace wireharness or connector. DI–725 DIAGNOSTICS – BODY CONTROL SYSTEM DI7NV–01 Engine Hood Courtesy Switch Circuit CIRCUIT DESCRIPTION The engine hood courtesy switch is built into the engine hood lock assembly and goes ON when the engine hood is opened and goes OFF when the engine hood is closed. WIRING DIAGRAM Body ECU E2 Engine Hood Courtesy SW J7 J/C 2 A A W–B 1 R–W 10 IE1 R–W 13 B8 HCTY W–B A J1 J/C IE I15497 2001 PRIUS (RM778U) DI–726 DIAGNOSTICS – BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check engine hood courtesy switch. PREPARATION: (a) Remove engine hood lock assembly. (b) Disconnect engine hood courtesy switch connector. CHECK: Check continuity between terminals 1 and 2 when engine hood lock is locked and unlocked. OK: 1 (+) 2 (–) Engine hood lock Tester connection Specified condition LOCK – No continuity UNLOCK 1–2 Continuity I00298 NG Replace engine hood courtesy switch. OK 2 Check harness and connector between body ECU and switch, switch and body ground (See page IN–41). NG OK Check and replace body ECU (See page IN–41). 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–727 DIAGNOSTICS – BODY CONTROL SYSTEM DI7NW–01 Luggage Courtesy Switch Circuit CIRCUIT DESCRIPTION The luggage courtesy switch goes on when luggage compartment door is opened and goes off when luggage compartment door is closed. WIRING DIAGRAM Body ECU R–W 1 D J/C D J30 J30 R–W 4 IF1 R–W 14 LCTY B8 L6 Luggage Compartment Light SW I15491 2001 PRIUS (RM778U) DI–728 DIAGNOSTICS – BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check luggage courtesy switch (See page BE–27). NG Replace the luggage courtesy switch. OK 2 Check wire harness and connector between luggage courtesy switch and body ECU (See page IN–41). NG OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–683). 2001 PRIUS (RM778U) Repair or replace wire harness or connector. DI–729 DIAGNOSTICS – BODY CONTROL SYSTEM DI2BN–05 Power window master switch circuit CIRCUIT DESCRIPTION Power window master switch circuit can be checked using DTC check. (See page DI–765) WIRING DIAGRAM P9 Power Window Master SW MPX1 Body ECU 18 Y 5 IG1 Y 6 B8 RX I15494 2001 PRIUS (RM778U) DI–730 DIAGNOSTICS – BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check the power window master switch circuit using DTC check. (See page DI–765) OK Proceed to next circuit inspection shown on problem symptom table (See page DI–683). OK 2 Check the power window master switch (See page BE–56). NG Replace the power window master switch. OK 3 Check wireharness and connector between power window master switch and body ECU. NG OK Proceed to next circuit inspection shown on problem symptom table (See page DI–683). 2001 PRIUS (RM778U) Repair or replace wireharness or connector. DI–731 DIAGNOSTICS – BODY CONTROL SYSTEM DI7NX–01 Power window switch circuit CIRCUIT DESCRIPTION Power window switch circuit can be checked using DTC check. (Refer to DI–762) WIRING DIAGRAM P6 Power Window Control SW Front RH 2 P11 Power Window Motor Front RH 1 Body ECU Y 5 U SU 6 R–W 7 IN1 R–W 3 B8 FLU G 2 D SD 1 G–B 5 IN1 G–B 2 B8 FLD P8 Power Window Control SW Rear RH 2 P13 Power Window Motor Rear RH 1 Y 5 U SU G 2 SD 1 D W 3 BB1 W 10 2J 14 B–W 4 BB1 B–W 5 5K 1 6 RRU RRD P7 Power Window Control SW Rear LH P12 Power Window Motor Rear LH Y 5 U L–O 3 BA1 L–O 2 2L 5 SU 6 G 2 D SD 1 G–R 4 BA1 G–R 1 2L 10 1 2 RLU RLD Instrument Panel J/B I15495 2001 PRIUS (RM778U) DI–732 DIAGNOSTICS – BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check the power window switch (See page DI–726). NG Replace the power window switch. OK 2 Check wireharness and connector between power window switch and body ECU (See page IN–41). NG OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–683). 2001 PRIUS (RM778U) Repair or replace wireharness or connector. DI–733 DIAGNOSTICS – BODY CONTROL SYSTEM DI7O0–01 Wireless door lock tuner circuit CIRCUIT DESCRIPTION The signal from the transmitter will be input to the body ECU through RDA line. RDA line is diagnosed by the body ECU, so check DTC also in case of the failure of the wireless function. WIRING DIAGRAM W5 Wireless Door Control Receiver Body ECU J27 J/C +B PRG RDA F 5 R–G F R–G 3 B–R 2 L 9 B9 S 7 B8 PRG 8 B8 RDA I15498 INSPECTION PROCEDURE 1 Check that DTC 42 is not output NG OK 2001 PRIUS (RM778U) Check the RDA line. DI–734 DIAGNOSTICS 2 – BODY CONTROL SYSTEM Check wireharness PREPARATION: Disconnect connectors of wireless door lock tuner and of body ECU. CHECK: Check continuity between terminals RCO of wireless door lock tuner and RCO of body ECU. OK: Continuity NG Repair or replace wireharness OK 3 Check the wireless door lock tuner CHECK: Replace the wireless door lock tuner and check if it recovers normally. OK: Must be recovered normally. NG NG Failure of the original wireless door lock tuner. 2001 PRIUS (RM778U) Proceed to next circuit inspection shown on problem symptoms table.(See page DI–683) DI–740 DIAGNOSTICS – DRIVER DOOR CONTROL SYSTEM DI2BM–11 CIRCUIT INSPECTION Power source circuit CIRCUIT DESCRIPTION This circuit provides power to operate the driver door ECU. WIRING DIAGRAM P9 Power Window Master SW Instrument Panel J/B 2 4 2D 2G B J24 L–Y C J25 L–Y 1 IG1 L–Y W–R 3 IC1 W–R 1 8 IC1 R–L 4 J20 J/C Instrument Panel J/B 11 J/C 20A PWR1 C 2J C R–L R–L 5 CPUB B IG 1 2H L–Y IG1 Relay 5A AM1 3 2B 6 2D 5 3 1 2 10A GAUGE 10 2K 8 2K I15 Ignition Switch IG1 4 B–Y 2 AM1 W–G FL Block No. 1 W 1 F11 1 F12 Engine Room J/B 7 1J 15A DOME 2 1B B 1 100A DC/DC F13 B–G F18 FL Block No. 2 120A MAIN 1 J11 J/C A W–B A W–B Battery ID IG 1 IC1 9 W–B E J17 J/C I15588 2001 PRIUS (RM778U) DI–741 DIAGNOSTICS – DRIVER DOOR CONTROL SYSTEM INSPECTION PROCEDURE 1 Check PWR1, AM1 and DOME fuse. CHECK: Check continuity of PWR1, AM1 and DOME fuse. OK: Continuity NG Replace the failure fuse. OK 2 Check voltage between terminals B, CPUB, IG and GND of driver door ECU connector. PREPARATION: Turn ignition switch ON. CHECK: Measure voltage between terminals IG, and GND. OK: Voltage: 10 – 14V PREPARATION: (a) Turn ignition switch OFF. (b) Disconnect the driver door ECU connector. CHECK: Measure voltage between terminals B, CPUB and GND. OK: Voltage: 10 – 14V OK NG 2001 PRIUS (RM778U) Proceed to next circuit inspection shown on problem symptoms table (See page DI–734). DI–742 DIAGNOSTICS 3 – DRIVER DOOR CONTROL SYSTEM Check wireharness and connector between ECU and body ground. NG OK Check and repair wireharness and connector between ECU and battery. 2001 PRIUS (RM778U) Repair or replace wireharness or connector DI–743 DIAGNOSTICS – DRIVER DOOR CONTROL SYSTEM DI2BP–08 Door unlock detection switch circuit CIRCUIT DESCRIPTION The door unlock detection switch is built in the door lock motor assembly. This switch is ON when the door lock knob is in the unlock position and OFF when the lock knob is in the lock position. The ECU detects the door lock knob conditions is this circuit. It is used as one of the operating conditions for the key confinement prevention function. WIRING DIAGRAM P9 Power Window Master SW D13 Door Unlock Detection Switch Front LH J/C J24 A J24 A 2 IG1 W–B Instrument Panel J/B W–B 8 2D 8 2K W–B W–B 4 W 3 10 LSWD J11 J/C A ID I15471 2001 PRIUS (RM778U) DI–744 DIAGNOSTICS – DRIVER DOOR CONTROL SYSTEM INSPECTION PROCEDURE 1 Check door unlock detection switch (See page BE–62). NG Replace the door lock motor. OK 2 Check wireharness and connector between door unlock detection switch and driver door ECU. NG OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–734). 2001 PRIUS (RM778U) Repair or replace wireharness or connector. DI–745 DIAGNOSTICS – DRIVER DOOR CONTROL SYSTEM DI2BQ–08 Door key lock and unlock switch circuit CIRCUIT DESCRIPTION The door key lock and unlock switch is built in the door key cylinder. When the key is turned to the lock side, terminal 3 of the switch is grounded and when the key is turned to the unlock side, terminal 2 of the switch is grounded. Door key lock and unlock switch can be checked using DTC check. (Refer to DI–765) WIRING DIAGRAM P9 Power Window Master SW D13 Door Key Lock and Unlock Switch J/C J24 A W–B J24 A W–B 2 IG1 UNLOCK W–B L–B 15 KUL G–Y KL 5 6 6 3 LOCK J11 Instrument Panel J/B J/C 8 8 W–B A 2K 2D ID I15472 2001 PRIUS (RM778U) DI–746 DIAGNOSTICS – DRIVER DOOR CONTROL SYSTEM INSPECTION PROCEDURE 1 Check the door key lock and unlock switch using DTC check (See page DI–765). OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–683). NG 2 Check the door key lock and unlock switch (See page BE–62). NG Replace the door key lock and unlock switch. NG 3 Check wireharness and connector between door key lock and unlock switch and driver door ECU. NG OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–734). 2001 PRIUS (RM778U) Repair or replace wireharness or connector. DI–747 DIAGNOSTICS – DRIVER DOOR CONTROL SYSTEM DI2BR–10 Door courtesy light and courtesy switch circuit CIRCUIT DESCRIPTION The door courtesy switch goes on when the door is opened and goes off when door is closed. WIRING DIAGRAM P9 Power Window Master SW D4 DIODE (Door Courtesy) 2 3 7 IC1 R–Y R–Y 16 DCTY R–W D7 Door Courtesy SW Front RH J16 J/C A A 1 R–W I15514 2001 PRIUS (RM778U) DI–748 DIAGNOSTICS – DRIVER DOOR CONTROL SYSTEM INSPECTION PROCEDURE 1 Check operation of door courtesy light. CHECK: Check that door courtesy light comes on when door opened, and goes off when door is closed. OK: Must be operated normally. OK Proceed to next circuit inspection shown on problem symptom table (See page DI–734). NG 2 Check courtesy light (See page BE–27). NG Replace the courtesy light. OK 3 Check courtesy switch (See page BE–27). NG Replace the courtesy switch. OK 4 Check wireharness and connector between courtesy light and driver door ECU, courtesy switch and driver door ECU. NG OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–734). 2001 PRIUS (RM778U) Repair or replace wireharness or connector. DI–749 DIAGNOSTICS – DRIVER DOOR CONTROL SYSTEM DI2BS–10 Power window motor circuit WIRING DIAGRAM P9 Power Window Master SW P10 Power Window Motor 1 Y 8 2 G 20 5 O 11 4 P–L 13 3 GR DU DON SGND LMT PLS I15516 2001 PRIUS (RM778U) DI–750 DIAGNOSTICS – DRIVER DOOR CONTROL SYSTEM INSPECTION PROCEDURE 1 Check power window motor (See page BE–56). NG Replace the power window motor. OK 2 Check wireharness and connector between power window motor and driver door ECU. NG OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–734). 2001 PRIUS (RM778U) Repair or replace wireharness or connector. DI–751 DIAGNOSTICS – DRIVER DOOR CONTROL SYSTEM DI2BT–09 Jam protection limit switch circuit CIRCUIT DESCRIPTION Jam protection limit switch is built–in the power window motor. This switch functions to turn ”OFF” before the top dead center, and ECU reads this ”OFF” signal resulting in closing the window fully. WIRING DIAGRAM P9 Power Window Master SW P10 Power Window Motor 1 Y 8 2 G 20 5 O 11 4 P–L 13 3 GR DU DON SGND LMT PLS I15516 2001 PRIUS (RM778U) DI–752 DIAGNOSTICS – DRIVER DOOR CONTROL SYSTEM INSPECTION PROCEDURE 1 Check jam protection limit switch (See page BE–56). NG Replace the power window motor. OK 2 Check wireharness and connector between jam protection limit switch and driver door ECU. NG OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–734). 2001 PRIUS (RM778U) Repair or replace wireharness or connector. DI–753 DIAGNOSTICS – DRIVER DOOR CONTROL SYSTEM DI2BU–09 Jam protection pulse switch circuit CIRCUIT DESCRIPTION Jam protection pulse switch is built–in the power window motor. Pulse switch outputs ON/OFF pulse when the motor rotates. WIRING DIAGRAM P9 Power Window Master SW P10 Power Window Motor 1 Y 8 2 G 20 5 O 11 4 P–L 13 3 GR DU DON SGND LMT PLS I15516 2001 PRIUS (RM778U) DI–754 DIAGNOSTICS – DRIVER DOOR CONTROL SYSTEM INSPECTION PROCEDURE 1 Check jam protection pulse switch (See page BE–56). NG Replace the power window motor. OK 2 Check wireharness and connector between jam protection pulse switch and driver door ECU. NG OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–734). 2001 PRIUS (RM778U) Repair or replace wireharness or connector. DI–757 DIAGNOSTICS – MULTIPLEX COMMUNICATION SYSTEM DI1SF–03 PRE–CHECK 1. (a) DIAGNOSIS SYSTEM As shown in the following illustration, each ECU of this vehicle is connected by communication bus and it transmits each signal by communication. This communication bus is self–diagnosed by Body ECU and it memorizes DTC when it detects communication stop to ECU or communication bus +B short or GND short. There is a possibility that Body ECU cannot self–diagnose accurately unless it doesn’t work normal. So, please note that the troubleshooting of Body Electrical System should be done after confirming if Body ECU and Open door indicator works normal by 2. ”BASIC INSPECTION” described later. DLC3 ECM Gateway ECU A/C Amplifier Body ECU Power Window Master Switch (Driver Door Control ECU) Combination Meter I15526 2001 PRIUS (RM778U) DI–758 DIAGNOSTICS ECU – MULTIPLEX COMMUNICATION SYSTEM (b) If DTC of ECU communication stop is output, there is a possibility of connector disconnection or 2 communication buses open. It will not become abnormal with only 1 communication bus open. (c) If 2 communication buses are open at the position as shown in the illustration, DTC of ECU communication stop between those 2 buses is output. ECU ECU Disconnection (DTC is detected) ECU ECU Open Open ECU Open (DTC is detected) ECU ECU Open ECU I03343 I03344 I03345 Open (DTC is not detected) I03977 Example Body ECU Open Open Detect the DTC of communication stop of the 3 ECUs. I03346 2001 PRIUS (RM778U) DI–759 DIAGNOSTICS 2. – MULTIPLEX COMMUNICATION SYSTEM BASIC INSPECTION INSPECT BODY ECU 1 Check room light operation. HINT: With this inspection body ECU CPU can be diagnosed if it works normal or not. CHECK: Check if the room light works normal at DOOR position. OK Go to next step”OPEN DOOR INDICATOR LIGHT INSPECTION”. NG 2 Check interior light system (Except body ECU) (See page BE–27). OK NG Repair of replace malfunction part. 2001 PRIUS (RM778U) Replace the body ECU. DI–760 DIAGNOSTICS – MULTIPLEX COMMUNICATION SYSTEM INSPECT OPEN DOOR INDICATOR LIGHT 1 Check open door indicator light. CHECK: Check if open door Indicator light is turned on when either door open. HINT: If open door Indicator light is not turned on, DTC will not be output. I15594 OK Go to step 3. ”DTC CHECK”. NG Repair the open door indicator light (See page BE–39). DLC3 3. (a) CG (b) (c) Tc A04550 2001 PRIUS (RM778U) DTC CHECK (Using diagnosis check wire) Using SST, connect terminals Tc and CG of DLC3. SST 09843–18020 Turn the ignition switch ON. Read the DTC on the open door indicator light. DI–761 DIAGNOSTICS – MULTIPLEX COMMUNICATION SYSTEM As an example, the blinking patterns for codes; normal, 12, and 11 and 12 are shown in the illustration. (d) Check for the problem using the DTC table on the next page. (e) After completing the check, turn the ignition switch off, and disconnect terminals Tc and E1. Normal Code 0.25 sec. 0.25 sec. Malfunction Code 12 1.5 sec. 0.5 sec. 4.5 sec. 0.5 sec. Malfunction Code 11 and 12 2.5 sec. 4.5 sec. N13628 4. (a) (b) (c) (d) DLC3 F12396 (e) DTC CHECK (Using hand–held tester) Prepare the hand–held tester. Connect the hand–held tester to DLC3. Turn the ignition switch ON and switch the hand–held tester main switch ON. Use the hand–held tester to check the DTCs, note them down. (For opening instructions, see the hand–held tester’s instruction book.) See page DI–757 to confirm the details of the DTCs. 5. DTC CLEARANCE DTC will be cleared when the trouble output to DTC is recovered normally. 2001 PRIUS (RM778U) DI–764 DIAGNOSTICS – MULTIPLEX COMMUNICATION SYSTEM DI7O1–01 TERMINALS OF ECU BODY ECU B9 B8 MPX2 MPX1 I15530 DRIVER DOOR ECU P8 MPX1 I15529 ECM E8 E9 E10 E11 MPX1 MPX2 I15592 2001 PRIUS (RM778U) DI–765 DIAGNOSTICS – MULTIPLEX COMMUNICATION SYSTEM A/C amplifier A9 A8 MP2+ A7 MPX+ I15590 Combination Meter ECU MPX+ C11 C10 L MPX– I15589 Multi Display TX3+ TX1+ M2 TX1– M3 M4 TX3– I15528 2001 PRIUS (RM778U) DI–766 DIAGNOSTICS – MULTIPLEX COMMUNICATION SYSTEM Gateway ECU GTX+ G1 GTX– MPD1 MPD2 I17261 Symbols (Terminals No.) IG ↔ GND (2 ↔ 14) Wiring Color B Y ↔ W–B B–Y W B Condition STD Value (V) Ignition switch OFF or ACC Below 1 V Ignition switch ON 10 – 14 V MDP1 (4) GR–B A/C ECU communication circuit – GTX+ (5) R AVC–LAN communication circuit – CG ↔ Body ground (7 ↔ Body ground) W–B ↔ Body ground Constant Below 1 V BATT ↔ GND (8 ↔ 14) R–G ↔ W–B Constant 10 – 14 V ACC ↔ GND (9 ↔ 14) GR R ↔ W–B GR–R W B Ignition switch OFF Below 1 V Ignition switch ACC or ON 10 – 14 V MDP2 (11) GR–L GTX– (12) G GND ↔ Body ground (14 ↔ Body ground) 2001 PRIUS (RM778U) W–B ↔ Body ground Engine and ECT ECU communication circuit – AVC–LAN communication circuit – Constant Below 1 V DI–767 DIAGNOSTICS – MULTIPLEX COMMUNICATION SYSTEM DI1SJ–03 CIRCUIT INSPECTION DTC B1211 / 11 Driver door ECU communication stop CIRCUIT DESCRIPTION This DTC is output when communication stops between driver door ECU and body ECU. DTC No. B1211/11 DTC Detecting Condition Trouble Area No communication from driver door ECU more than 10 se seconds.
Driver door ECU
Wireharness WIRING DIAGRAM P9 Power Window Master SW MPX1 Body ECU 18 Y 5 IG1 6 Y B8 RX I15494 2001 PRIUS (RM778U) DI–768 DIAGNOSTICS – MULTIPLEX COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 Check driver door ECU. CHECK: Check if the driver door window glass auto up. HINT: With this inspection, the driver door ECU CPU can be diagnosed if it works normally or not. NG OK 2001 PRIUS (RM778U) Replace the driver door ECU. DI–769 DIAGNOSTICS 2 – MULTIPLEX COMMUNICATION SYSTEM Check wireharness. PREPARATION: Disconnect connector ”B8” of body ECU and ”P9” of driver door ECU. CHECK: Check continuity between terminal RX of body ECU and MPX1 of driver door ECU. OK: There is a continuity in wireharness. HINT: If there is OPEN in wireharness, please repair it. Body ECU Driver Door ECU RX MPX1 I15549 NG OK Replace the driver door ECU. 2001 PRIUS (RM778U) Repair or replace wireharness. DI–771 DIAGNOSTICS – MULTIPLEX COMMUNICATION SYSTEM DI1SS–05 DTC B1242 / 42 Wireless door lock tuner circuit malfunction CIRCUIT DESCRIPTION This DTC is output when GND short of RDA terminal is detected. DTC No. B1242/42 DTC Detecting Condition Trouble Area
Wireharness
Wireless door lock tuner
Body ECU GND short of RDA terminal WIRING DIAGRAM W5 Wireless Door Control Receiver (Tuner) Body ECU J27 J/C +B PRG RDA 5 3 2 R–G F F R–G 9 B9 S B–R 7 B8 PRG L 8 B8 RDA I15498 2001 PRIUS (RM778U) DI–772 DIAGNOSTICS – MULTIPLEX COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 Check wireharness. Tuner RDA Body ECU PREPARATION: Disconnect the connector of tuner and body ECU. CHECK: Check the continuity between wireharness and body ground. OK: No continuity. I03347 NG Repair or replace the wireharness. OK 2 Check body ECU. Tuner PREPARATION: Connect the connector of body ECU. CHECK: Check the DTC. OK: B1242/42 is not output. Body ECU I03348 NG OK Replace the tuner. 2001 PRIUS (RM778U) Replace the body ECU. DI–773 DIAGNOSTICS – MULTIPLEX COMMUNICATION SYSTEM DI7O2–01 DTC B1248/48 AVC–LAN circuit communication stop CIRCUIT DESCRIPTION This DTC is output when communication stops between gateway ECU and AVC–LAN circuit. The body ECU performs the diagnosis check of the gateway ECU communication error to ”AVC–LAN”. The condition of registration can be checked by DTC of the body ECU. DTC No. B1248/48 DTC Detecting Condition C diti th Condition thatt th the gateway t ECU cannott register i t tto AVC AVC–LAN. LAN Trouble Area
Gateway ECU
Wireharness WIRING DIAGRAM G1 Gateway ECU Multi Display TX3+ M5 R R 5 4 G TX3– M5 11 GTX+ G 12 GTX– I15475 2001 PRIUS (RM778U) DI–774 DIAGNOSTICS – MULTIPLEX COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 Check ”Service check mode” of audio sysytem. (AVC–LAN diagnosis check) (See page DI–791) CHECK: Connection of the gateway ECU can be checked by AVC–LAN diagnosis. (”Service check mode” of audio sysytem) OK: Display G/W: OK (Sysytem is normal) G/W: NG (Communication error) G/W: None (Never registered) NG Replace the gateway ECU. OK 2 Check wireharness Multi Display TX3+ Gateway ECU TX3– GTX+ PREPARATION: Disconnect connector ”G1” of gateway ECU and ”M2” of multi display. CHECK: (a) Check continuity between terminals GTX+ of gateway ECU and TX3+ of multi display. (b) Check continuity between terminals GTX– of gateway ECU and TX3– of multi display. OK: There is a continuity in wireharness of both (a) and (b), or either (a) or (b). HINT: If there is OPEN in wireharness of either (a) or (b), please repair it. GTX– I15538 OK Replace the gateway ECU. 2001 PRIUS (RM778U) NG Repair or replace wireharness. DI–775 DIAGNOSTICS – MULTIPLEX COMMUNICATION SYSTEM DI1SV–05 DTC B1261 / 61 ECM communication stop CIRCUIT DESCRIPTION This DTC is output when communication stops between ECM and body ECU. DTC No. B1261/61 DTC Detecting Condition Trouble Area N communication No i ti from f ECM more than th 10 seconds. d
ECM
Wireharness WIRING DIAGRAM G1 Gateway ECU C11 Combination Meter 2 GR–B MPX– 3 MPX+ A7 A/C Amplifier 11 GR B8 Body ECU 15 MPX+ MPX– MP2+ 4 MPX+ 4 GR–B MPD1 E10 Engine Control Module 13 16 GR MPX1 14 MPX2 GR–L 11 MPD2 I15474 2001 PRIUS (RM778U) DI–776 DIAGNOSTICS – MULTIPLEX COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 Check ECM. CHECK: Check that the engine starts normally. HINT: With this inspection, ECM CPU can be diagnosed if it works normally or not. NG OK 2001 PRIUS (RM778U) Replace the ECM. DI–777 DIAGNOSTICS 2 – MULTIPLEX COMMUNICATION SYSTEM Check wireharness PREPARATION: Disconnect connector ”B8” of body ECU, ”E11” of ECM and ”G1” of gateway ECU. CHECK: (a) Check continuity between terminals MPX– of body ECU and MPX2 of ECM. (b) Check continuity between terminals MPX1 of ECM and MPX1 of gateway ECU. OK: There is a continuity in wireharness of both (1) and (2), or either (1) or (2). HINT: If there is OPEN in wireharness of either (1) or (2), please repair it. Body ECU MPX– ECM Gateway ECU MPX1 MPX2 MPX1 I15537 NG OK Replace the ECM. 2001 PRIUS (RM778U) Repair or replace wireharness. DI–779 DIAGNOSTICS – MULTIPLEX COMMUNICATION SYSTEM DI7O3–01 DTC B1266 / 66 Instrument panel system communication bus malfunction (+B short) DTC B1267 / 67 Instrument panel system communication bus malfunction (GND short) CIRCUIT DESCRIPTION This DTC is output when +B or GND short occurs on instrument panel system communication bus. If +B or GND short is detected on instrument panel system communication bus, separate it by bus cut relay in body ECU to prevent while communication buses’ failure. WIRING DIAGRAM G1 Gateway ECU C11 Combination Meter 2 GR–B MPX– 3 MPX+ A7 A/C Amplifier 11 GR B8 Body ECU 15 MPX1 MPX– MP2+ 4 MPX+ 4 GR–B E11 Engine Control Module 13 16 GR MPX1 14 MPX2 GR–L 11 I15474 2001 PRIUS (RM778U) DI–780 DIAGNOSTICS – MULTIPLEX COMMUNICATION SYSTEM INSPECTION PROCEDURE HINT: On the system structure point of view, this DTC cannot display meter. In case of checking DTC, please use hand–held tester. 1 Check the communication circuit inside ECM. PREPARATION: Disconnect the connector ”E11” of ECM. CHECK: Check the DTC. OK: Code B1266 or B1267 is not output ECM E11 I15546 OK Replace the ECM. NG 2 Check the communication circuit inside gateway ECU. PREPARATION: (a) Connect the connector ”E11” of ECM. (b) Disconnect the connector ”G1” of gateway ECU. CHECK: Check the DTC. OK: Code B1266 or B1267 is not output Gateway ECU G1 I15545 OK NG 2001 PRIUS (RM778U) Replace the gateway ECU. DI–781 DIAGNOSTICS 3 – MULTIPLEX COMMUNICATION SYSTEM Check the communication circuit inside A/C amplifier. A/C Amplifier A7 PREPARATION: (a) Connect the connector of ”G1” of gateway ECU. (b) Disconnect the connector ”A7” of A/C amplifier. CHECK: Check the DTC. OK: Code B1266 or B1267 is not output I15544 OK Replace the A/C amplifier. NG 4 Check the communication circuit inside combination meter ECU. PREPARATION: (a) Connect the connector ”A7” of A/C amplifier. (b) Disconnect the connector ”C11” of combination meter ECU. CHECK: Check the DTC. OK: Code B1266 or B1267 is not output Combination Meter C11 I15543 OK NG 2001 PRIUS (RM778U) Replace the combination meter ECU. DI–782 DIAGNOSTICS 5 – MULTIPLEX COMMUNICATION SYSTEM Check for short circuit between combination meter ECU and body ECU. PREPARATION: Disconnect the connector ”B8” of body ECU. CHECK: Check the DTC. OK: Code B1266 or B1267 is not output Body ECU B8 I15542 OK Repair or replace the wireharness between combination meter ECU and body ECU. NG 6 Check for short circuit between body ECU and ECM. PREPARATION: Connect the connector ”B8” of body ECU. Disconnect the connector ”E11” of ECM. CHECK: Check the DTC. OK: Code B1266 or B1267 is not output Body ECU B8 E11 I15542 I15546 I18344 OK NG 2001 PRIUS (RM778U) Repair or replace the wireharness between body ECU and ECM. DI–783 DIAGNOSTICS 7 – MULTIPLEX COMMUNICATION SYSTEM Check for short circuit between ECM and gateway ECU. PREPARATION: Connect the connector ”B8” of body ECU. Disconnect the connector ”G1” of gateway ECU. CHECK: Check the DTC. OK: Code B1266 or B1267 is not output Gateway ECU G1 I15545 OK Repair or replace the wireharness between ECM and gateway ECU. NG 8 Check for short circuit between gateway ECU and A/C amplifier. A/C Amplifier A7 PREPARATION: Connect the connector ”E11” of ECM. Disconnect the connector ”A7” of A/C amplifier. CHECK: Check the DTC. OK: Code B1266 or B1267 is not output I15544 OK NG 2001 PRIUS (RM778U) Repair or replace the wireharness between ECM and A/C amplifier. DI–784 DIAGNOSTICS 9 – MULTIPLEX COMMUNICATION SYSTEM Check for short circuit between A/C amplifier and combination meter ECU. PREPARATION: Connect the connector ”A7” of A/C amplifier. Disconnect the connector ”C11” of combination meter ECU. CHECK: Check the DTC. OK: Code B1266 or B1267 is not output Combination Meter C11 I15543 OK NG Replace the body ECU. 2001 PRIUS (RM778U) Repair or replace the wireharness between A/C amplifier and combination meter ECU. DI–785 DIAGNOSTICS – MULTIPLEX COMMUNICATION SYSTEM DI1SY–03 DTC B1271 / 71 Combination meter ECU communication stop CIRCUIT DESCRIPTION This DTC is output when communication stops between combination meter ECU and body ECU. DTC No. DTC Detecting Condition Trouble Area B1271/71 No communication from Combination meter ECU more than 10 seconds.
Combination meter ECU
Wireharness WIRING DIAGRAM See page DI–770 INSPECTION PROCEDURE 1 Check combination meter ECU. CHECK: Start the engine and check that the speed meter and tacometer operate normally. HINT: With this inspection, the combination meter ECU CPU can be diagnosed if it works normally or not. NG OK 2001 PRIUS (RM778U) Replace the combination meter ECU. DI–786 DIAGNOSTICS 2 – MULTIPLEX COMMUNICATION SYSTEM Check wireharness Combination Meter A/C amplifier MPX+ MPX– Body ECU Combination Meter PREPARATION: Disconnect connector ”A7” of A/C amplifier, ”C11” of combination meter ECU and ”B8” of body ECU. CHECK: (a) Check continuity between terminals MPX+ of A/C amplifier and MPX– of combination meter ECU. (b) Check continuity between terminals MPX+ of combination meter ECU and MPX1 of body ECU. OK: There is a continuity in wireharness of both (a) and (b), or either (a) or (b). HINT: If there is OPEN in wireharness of either (a) or (b), please repair it. ”C6” MPX+ MPX1 I15539 NG OK Replace the combination meter ECU. 2001 PRIUS (RM778U) Repair or replace wireharness. DI–787 DIAGNOSTICS – MULTIPLEX COMMUNICATION SYSTEM DI1SY–04 DTC B1274/74 Multi display communication stop CIRCUIT DESCRIPTION This DTC is output when communication stops between multi display and body ECU. DTC No. B1274/74 DTC Detecting Condition N communication No i ti from f multi lti display di l more than th 10 seconds. d WIRING DIAGRAM See Page DI–770 2001 PRIUS (RM778U) Trouble Area
Multi display dis lay
Wireharness DI–788 DIAGNOSTICS – MULTIPLEX COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 Check multi display ECU. CHECK: Check that the multi display operate normally. HINT: With this inspection, the multi display CPU can be diagnosed if it works normally or not. NG Replace the multi display. OK 2 Check wireharness. Multi Display TX3+ Gateway ECU TX3– PREPARATION: Disconnect connector ”M2” of multi display and ”G1” of gateway ECU. CHECK: (a) Check continuity between terminals TX3+ of multi display and GTX+ of gateway ECU. (b) Check continuity between terminals TX3– of multi display and GTX– of gateway ECU. OK: There is a continuity in wireharness. HINT: If there is OPEN in wireharness, please repair it. GTX+ GTX– I15538 NG OK Replace the multi display. 2001 PRIUS (RM778U) Repair or replace wireharness. DI–789 DIAGNOSTICS – MULTIPLEX COMMUNICATION SYSTEM DI1SY–05 DTC B1293/93 Gateway ECU communication stop CIRCUIT DESCRIPTION This DTC is output when communication stops between gateway ECU and body ECU. DTC No. DTC Detecting Condition Trouble Area B1293/93 N communication No i ti from f gateway t ECU more than th 10 seconds. d
Gateway ECU
Wireharness WIRING DIAGRAM See page DI–770 INSPECTION PROCEDURE 1 Check open door warning light. CHECK: Connection that the gateway ECU and BEAN (Body Electrical Area Network) can be checked by DTC transmitted by the body ECU. See ”INSPECT OPEN DOOR INDICATOR LIGHT on page DI–752. NG OK 2001 PRIUS (RM778U) Replace the gateway ECU. DI–790 DIAGNOSTICS 2 – MULTIPLEX COMMUNICATION SYSTEM Check wireharness PREPARATION: Disconnect connector ”B8” of body ECU, ”E11” of ECM and ”G1” of gateway ECU. CHECK: (a) Check continuity between terminals MPX– of body ECU and MPX2 of ECM. (b) Check continuity between terminals MPX1 of ECM and MPX1 of gateway ECU. OK: There is a continuity in wireharness of both (a) and (b), or either (a) or (b). HINT: If there is OPEN in wireharness of either (a) or (b), please repair it. Body ECU MPX– ECM Gateway ECU MPX1 MPX1 MPX2 I15537 NG OK Replace the gateway ECU. 2001 PRIUS (RM778U) Repair or replace wireharness. DI–791 DIAGNOSTICS – MULTIPLEX COMMUNICATION SYSTEM DI7O4–01 Power Source Circuit CIRCUIT DESCRIPTION This circuit provides power to operate the gateway ECU. 2001 PRIUS (RM778U) DI–792 DIAGNOSTICS – MULTIPLEX COMMUNICATION SYSTEM WIRING DIAGRAM G1 Gateway ECU GR–R R–G Instrument Panel J/B 8 2C 5 3 1 2 R–G 1 2H W 5A AM1 3 2B 6 2D J/C C J26 9 GR–R 7.5 A ECU–B 5 2C P–L ACC Relay 10A ACC 2 2D C J25 IG1 Relay 5 5A ECU–IG 3 1 F J/C H J25 J26 BATT B–Y 8 2K 2 8 R–G 2 2I ACC J14 J/C D Instrument Panel J/B D B–Y 1 2 AM1 B–Y FL Block No.1 I15 Ignition Switch IG1 4 100A DC/DC F11 1 5 F13 ID1 W–G B–Y ACC 3 B–G J19 J/C F18 FL Block No.2 D W D 120A MAIN FL 1 W–B 2 B–Y W–B 14 W–B A A J22 J/C W–B 2001 PRIUS (RM778U) GND 7 E CG W–B Instrument Panel J/B J11 J/C ID E W–B A A Battery A J19 J/C E J/C D J20 J21 IG 8 W–B 2D 8 2K A W–B J11 J/C ID I17118 DI–793 DIAGNOSTICS – MULTIPLEX COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 Check ECU–B and ECU–IG fuse. CHECK: Check continuity of ECU–B and ECU–IG fuse. OK: Continuity NG Replace the failure fuse. OK 2 Check voltage between terminals BATT, IG and GND of body ECU connector. PREPARATION: (a) Turn ignition switch OFF. (b) Disconnect the gateway ECU connector. CHECK: Measure voltage between terminals BATT and GND. OK: Voltage: 10 – 14 V OK Check and repair wireharness and connector between gateway ECU and battery. NG 3 Check wireharness and connector between gateway ECU and body ground (See page IN–41). NG OK Check and repair wireharness and connector between gateway ECU and battery. 2001 PRIUS (RM778U) Repair or replace wireharness or connector. DI–796 DIAGNOSTICS – NAVIGATION SYSTEM DI7OR–01 PRE–CHECK 1. DIAGNOSIS SYSTEM MODE HINT: Diagnosis System Mode is operated as follows. Navigation system normal operation Diagnosis start–up. (refer to next page) to 2. SYSTEM CHECK MODE SCREEN HINT: When Diagnosis System mode is started, system check is performed at first and the check result is displayed. to 3. NAVIGATION CHECK MODE SCREEN to 4. DISPLAY CHECK MODE SCREEN I17101 2001 PRIUS (RM778U) DI–797 DIAGNOSTICS – NAVIGATION SYSTEM (a) DIAGNOSIS START–UP To start the diagnosis menu, there are 2 ways: using a diagnosis check wire and using a switch. (b) START–UP BY SWITCH OPERATION (1) Vehicle speed is 0 km/h (0 mph). (2) Parking brake switch is pressed. (3) Press the Display switch to display the Screen Adjustment screen. I15593 (4) Concealed touch switch Repeatedly touch the upper and lower bottom parts of the left end of the screen 3 times. I17110 (c) 2001 PRIUS (RM778U) FINISHING DIAGNOSIS SYSTEM MODE Turn the ignition switch from ACC to OFF to finish the mode. If it is started by switch operation. DI–798 DIAGNOSTICS – NAVIGATION SYSTEM 2. SERVICE CHECK MODE HINT: Service Check Mode is operated as follows. DTC memory and history clear DTC memory clear Recheck to 1. Diagnosis MENU screen When there are individual DTC data. Yes No DTC clear I15446 2001 PRIUS (RM778U) DI–799 DIAGNOSTICS (a) – NAVIGATION SYSTEM SERVICE CHECK SCREEN Diagnosis MENU screen switch Components name Recheck DTC clear switch Check result Memory clear switch I15447 (1) By performing system check and collecting data of diagnosis memory, this mode checks the current and past condition of the vehicle. (2) List of all components name or physical addresses. It displays only the components that have been connected at least once. (3) The check result is displayed for all components. (4) The check result is displayed by 6 abbreviations: ”OK”, ”EXCH”, ”CHEK”, ”NCON”, ”NRES” and ”Old”. (”EXCH”, ”CHEK” and ”Old” have a function as switches.) (5) Based on all information obtained from ”System Check Request”, ”Diagnosis Memory Request” and ”Current Diagnosis Result” command, the following results are displayed: OK: No error is identified. EXCH: One or more error codes requesting for exchange are detected in any check result. CHEK: Except the conditions for ”EXCH”, one or more error codes requesting for check are detected in any check result. (6) The other check results are as follows: NCON: No response to ”Diagnosis ON Instruction” command and it is not connected when the system is started. Old: One or more error codes are detected when responding to ”Diagnosis ON Instruction” command because of the old version . NRES: No response to all commands of ”System Check Request”, ”Diagnosis Memory Request” and ”Current Diagnosis Result”. Or no error is detected by any one of ”System Check Request” or ”Diagnosis Memory Request” when no response to the other command. (7) ”EXCH”, ”CHEK” and ”Old” are functioned as switches any by pressing these, LAN Check Mode and Unit Check Mode are activated. (8) Memory Clear Switch Pressing this switch for 3 sec. deletes all information about master component registration and diagnosis memory of all components. (9) DTC Clear Switch Pressing this switch for 3 sec. deletes diagnosis memory of all components. (10) Recheck Switch Pressing this switch rechecks the system. (11) Menu Switch Pressing this switch activated the Diagnosis Menu Screen. 2001 PRIUS (RM778U) DI–800 DIAGNOSTICS (b) – NAVIGATION SYSTEM LAN CHECK MODE SCREEN Components name Service check mode screen switch Unit check mode screen switch Number of occurrence DTC clear switch Segment DTC Connection confirmation number Related components parts I15448 (1) (2) As a detailed screen in the System Check Mode, LAN Check Mode is displayed. Communication codes (logical address ”01”) are extracted from the diagnosis data obtained by ”Diagnosis Memory Request” and displayed. (3) Component Name Names of the components to be checked are displayed. (4) Segment Logical address codes corresponding to DTC are displayed. (5) DTC DTC displayed. (6) Related components address Physical address codes corresponding to DTC are displayed. (7) Connection Confirmation Number Connection confirmation numbers corresponding to DTC is displayed. (8) Number of Occurrence The number of occurrence of the same DTC is displayed. (9) DTC Clear Switch Pressing this switch for 3 sec. deletes DTC memory of the selected diagnosis component. When returning to the System Check Mode, the check result is shown as a blank. (10) Unit Check Mode Screen Switch Pressing this switch activates the Unit Check Mode screen. (11) System Check Mode Screen Switch Pressing this switch activates the System Check Mode screen. 2001 PRIUS (RM778U) DI–801 DIAGNOSTICS (c) – NAVIGATION SYSTEM UNIT CHECK MODE SCREEN Components name System check mode screen switch LAN check mode screen switch DTC clear switch Segment Year/Month/Day Segment DTC DTC Hour/Minute/Second I15449 (1) (2) (3) (4) (5) (6) (7) As a detailed screen in the System Check Mode, the Unit Check Mode is displayed. Up to 6 error codes detected by ”The DTC obtained during the system check (including when starting the diagnosis mode)” can be displayed as ”Current”. Up to 6 error codes detected by ”DTC stored in the past” can be displayed as ”Memory”. Component Name Names of the components are displayed. Segment Logical address numbers corresponding to DTC are displayed. DTC DTC is displayed. Year/Month/Day/Hour/Minute/Second The date and time stamped at the time of code occurrence is displayed in the order of year– month–day–hour–minute–second. (Year is shown in 2–digit number.) If the date and time data is invalid, it is displayed as a blank. HINT: Time data is obtained after turning the ignition from ACC to ON. Until the valid time data is obtained, the data shown in the display shall be considered as invalid. If stored before a valid time data is obtained, the data shall not be displayed. (8) DTC Clear Switch Pressing this switch for 3 sec. deletes all diagnosis memory of the component. When returning to the System Check Mode, the check result is displayed as a blank. (9) Lan Check Mode Screen Switch Pressing this switch activates the LAN Check Mode screen. (10) System Check Mode Screen .Switch Pressing this switch activates the System Check Mode screen. 2001 PRIUS (RM778U) DI–802 DIAGNOSTICS – NAVIGATION SYSTEM 3. NAVIGATION CHECK MODE HINT: Navigation Check Mode is operated as follows. to 1. Diagnosis MENU screen The Microphone Check screen is not applicable to the Prius. I17100 2001 PRIUS (RM778U) DI–803 DIAGNOSTICS (a) – NAVIGATION SYSTEM NAVIGATION CHECK MODE SCREEN GPS information mode screen switch Diagnosis MENU screen switch Vehicle sensor mode screen switch Color bar check mode screen switch I17095 (1) (2) (3) (4) (5) Various check screens for the Navigation ECU can be started from this menu screen. GPS Information Mode Screen Switch Pressing this switch activates GPS Information Mode Screen. Vehicle Sensor Mode Screen Switch Pressing this switch activates the Vehicle Signal Mode screen. Color Bar Check Mode Screed Switch Pressing this switch activates the Color Bar Check Mode screen. Diagnosis Menu Screen Switch Pressing this switch activates the Diagnosis Menu screen. 2001 PRIUS (RM778U) DI–804 DIAGNOSTICS (b) – NAVIGATION SYSTEM GPS INFORMATION MODE SCREEN Navigation Check screen switch Time data Satellite Information Measurement Status Position data I17096 (1) This screen displays GPS related data. HINT: Data are updated every 1 sec. (2) Satellite Information The angle of elevation of relevant satellite, azimuth signal level, and receiving condition of signals are displayed. HINT: The reception status shows receiving. ”T”: means in operation but measurement is not being used for positioning. ”P”: means measurement is being used for positioning. ”–”: means no data can be received. Display area for up to 8 satellites is ensured. Data shall be updated corresponding to change of information. (3) Time data: The time data obtained from a GPS receiver is displayed in month, day, year, hour and minute. (4) The displayed time is Greenwich Mean Time. (5) Position Data: The latitude and longitude of the current location are displayed in degree and minute. (6) Measurement Status is displayed in the following 5 items. 2D: 2 dimensions. 3D: 3 dimensions. NG: GPS information cannot be used. error: Receiving error occurs. –: Other than the above. (7) Navigation Check Screen Switch Pressing this switch activates the Navigation Check screen. 2001 PRIUS (RM778U) DI–805 DIAGNOSTICS (c) – NAVIGATION SYSTEM VEHICLE SIGNAL CHECK MODE SCREEN Navigation check screen switch I17097 (1) Status of the vehicle sensor which are input to the Navigation ECU is checked in this screen. HINT: Data are updated every 1 sec. (2) ACC signal status: Displayed as ON/OFF. (3) REV signal status: Displayed as ON/OFF. (4) SPD signal status: The following is displayed:
The cumulative value of the input pulse after displaying this screen. (shown in 5 digits)
Vehicle speed (Unit: km/h, mph) (5) Output condition of the gyro sensor: The following is displayed:
Voltage (Unit: mV, LSB: 1mV)
Relative azimuthal angle to the current point (0 degree). Assuming the angle at a point when this screen is activated as 0 degree. (6) Navigation Check Menu Screen Switch Pressing this switch displays the Navigation Check screen. 2001 PRIUS (RM778U) DI–806 DIAGNOSTICS (d) – NAVIGATION SYSTEM COLOR BAR CHECK MODE SCREEN Navigation check screen switch I17098 (1) (2) (3) Color display of the Navigation ECU is checked in this screen. Color Bars: Five colors of ”BLACK”, ”RED”, ”GREEN”, ”BLUE” and ”WHITE” are displayed as bars. Navigation Check Screen Switch Pressing this switch displays the Navigation Check screen. 2001 PRIUS (RM778U) DI–807 DIAGNOSTICS – NAVIGATION SYSTEM 4. DISPLAY CHECK MODE HINT: Display Check Mode is operated as follows. to 1. Diagnosis MENU mode screen switch I15454 2001 PRIUS (RM778U) DI–808 DIAGNOSTICS (a) – NAVIGATION SYSTEM DISPLAY CHECK MENU SCREEN Color bar check mode switch Touch switch check mode switch to 1. Diagnosis MENU screen switch Touch point check mode switch Vehicle signal check mode switch I15453 (1) (2) (3) (4) (5) (6) Various screens to check the display are started from this screen. Color Bar Check Mode Switch Pressing this switch activates the Color Bar Check Mode screen. Touch Switch Check Mode Switch Pressing this switch activates the Touch Switch Check Mode screen. Touch Point Check Mode Switch Pressing this switch activates the Touch Point Check Mode screen. Vehicle Signal Check Mode Switch Pressing this switch activates the Vehicle Signal Check Mode screen. Diagnosis MENU Screen Switch Pressing this switch activates the Diagnosis MENU screen. 2001 PRIUS (RM778U) DI–809 DIAGNOSTICS (b) – NAVIGATION SYSTEM COLOR BAR CHECK MODE SCREEN to Display check screen switch I15456 (1) (2) Color display is checked in this screen. Color Bar: Black, Red, Green, Blue, White and Stripe is displayed in bars. If a bar is touched, color or stripe of the bar is appeared all over the screen. When touched again, it returns to the previous screen. (3) Display Check Screen Switch Pressing this switch activates the Display Check Mode screen. 2001 PRIUS (RM778U) DI–810 DIAGNOSTICS (c) – NAVIGATION SYSTEM TOUCH SWITCH CHECK MODE SCREEN Horizontal line check screen switch Display check screen switch I18203 (1) (2) (3) (4) Operating condition is checked line by line in the Touch Switch Check Mode screen. Check Line: Lines are displayed by using infrared beams in this screen. Once a beam is blocked off by touching the screen with a fingertip, the blocked part of the line is deleted. Horizontal Line Check Screen Switch: Pressing this switch activates a screen in which beams of horizontal lines are checked. Display Check Mode Switch Pressing this switch activates the Display Check Mode screen. 2001 PRIUS (RM778U) DI–811 DIAGNOSTICS (d) – NAVIGATION SYSTEM TOUCH POINT CHECK MODE SCREEN Display check screen switch Press point I15462 (1) (2) (3) In this screen, the position detected by the pressure sensing touch switch is checked. Press point: The detected point is indicated by a cross–hair cursor. Display Check Screen Switch Pressing this switch activates the Display Check Mode screen. 2001 PRIUS (RM778U) DI–812 DIAGNOSTICS (e) – NAVIGATION SYSTEM VEHICLE SIGNAL CHECK MODE SCREEN Display check screen switch I15461 (1) (2) (3) Status of the Vehicle Signal which has been loaded into the display is checked in this screen. Signal Description Battery: Displays battery voltage in V. IG: Displays ON or OFF of the ignition switch. PKB: Displays ON (applied) or OFF (released) of the parking brake. SPEED: Displays the vehicle speed in km/h. TAIL: Displays ON or OFF of the tail light switch. Display Check Screen Switch Pressing this switch activates the Display Check Mode screen. 2001 PRIUS (RM778U) DI–813 DIAGNOSTICS – NAVIGATION SYSTEM DI27Z–05 DIAGNOSTIC TROUBLE CODE CHART Meaning Terms Physical address Three–digit code (shown in hexadecimal) which is given to each component comprising the AVC – LAN Corresponding to the function, individual symbols are specified.. Logical address Two–digit code (shown in hexadecimal) which is given to each function comprising the inner system of the AVC – LAN. Physical address: 110 Multi display Logical address DTC Diagnosis item Diagnosis content Panel Switch Error in panel switch input part is detected. Error (Error in switch control part, or internal communication error with switch control part is detected.) Countermeasure and inspected parts
Inspect all switches on touch switch test screen in display check mode. If any of lines and point does not react, replace multi–display assembly.
If all switches function without problem, observe them for a while.
Inspect all touch switches on touch switch test screen in display check mode. If any of lines does not react, replace multi–display assembly.
If all of vertical and horizontal lines react normally, observe them for a while. 21 *1 (Switch) 10 21 (Switch) 11 Touch Switch Error 34 (Front passenger monitor) 10 Error in Picture Error in power supply system for Replace multi–display assembly. picture circuit (abnormal voltage) is Circuit detected. 34 (Front passenger monitor) 11 Backlight Error Decline in power output from inverter circuit for backlight. (No current) Replace multi–display assembly. 34 (Front passenger monitor) 12 Backlight Error Excess power output from inverter (Excess circuit for backlight. current) Replace multi–display assembly. 01 (Communication control) 21 ROM Error Abnormal condition of ROM is detected. Replace multi–display assembly. 01 (Communication control) 22 RAM Error Abnormal condition of RAM is detected. Replace multi–display assembly. Error in touch switch sensor is detected. *1: Check if the operation in Touch Point Check or Touch Switch Check screen is normal. If it operates without any problem, see how things go for a while. Although this code is defined as Panel Switch Error, there are touch switches only on the display. If the internal communication is erroneous, however, this code is stored. 2001 PRIUS (RM778U) DI–814 DIAGNOSTICS 01 *2 D5 (Communication Control) Registered component disconnected – NAVIGATION SYSTEM Component shown by auxiliary code is or was disconnected from system with ignition switch in ACC or ON. Communication with component shown by auxiliary code is not established when engine is started.
Check harness for power supply of component shown by auxiliary code
Check harness for communication system of component shown by auxiliary code No response to Component shown by auxiliary
Check harness for power supply code is or was disconnected from of component shown by auxiliary connection code system after engine is started. check
Check harness for communication system of component shown by auxiliary code 01 *3 (Communication Control) D8 01 *2 (Communication Control) D9 Last Mode Error Component operated (sound and/ or image was provided) before engine stop is or was disconnected with ignition switch in ACC or ON.
Check harness for power supply of component shown by auxiliary code
Check harness for communication system of component shown by auxiliary code 01 (Communication Control) DA No Response to ON/OFF Instruction No response is identified when changing mode (audio and visual mode change). Detected when sound and picture does not change by button operation.
Check harness for power supply of component shown by auxiliary code.
Check harness for communication system of component shown by auxiliary code.
If error occurs again, replace component shown by auxiliary code. 01 *2 (Communication Control) DB Mode Status Error Dual sound is detected.
Check harness for power supply system of component shown by auxiliary code.
Check harness for communication system of component shown by auxiliary code. 01 *4 (Communication Control) DC Transmission Error Transmission to component shown by auxiliary code has been failed. (This code does not necessarily mean actual failure.) If same component shown by auxiliary code is recorded in other component(s), check harness for power supply and communication system of components shown sub code. 01 *5 (Communication Control) DE Slave Reset (Momentary Interruption) After engine start, slave component
Check harness for power supply has been disconnected. system of component shown by DB auxiliary code.
Check harness for communication system of component shown by auxiliary code. 01 *1 (Communication Control) E4 Multiple Frame Multiple frame transmission is Since this DTC is provided for engineering, it may be detected when Abort aborted. no actual failure exists. *2: Even if no failure is detected, it may be stored depending on the battery condition or voltage for starting an engine. *3: It is stored when 180 sec. has passed after the power supply connector is pulled out after engine start. *4: It may be stored when the engine key is turned again 1 min. after engine start. *5: It may be stored when the engine key is turned again after engine start. 2001 PRIUS (RM778U) DI–815 DIAGNOSTICS – NAVIGATION SYSTEM Physical address: 190 Radio receiver assembly Logical address DTC Diagnosis item Diagnosis content Countermeasure and inspected parts 01 (Communication Control) 21 ROM Error Error is detected in internal ROM. Replace radio receiver assembly. 01 (Communication Control) 22 RAM Error Error is detected in internal RAM. Replace radio receiver assembly. 01 *2 (Communication Control) D6 Absence of Master Component in which this code is recorded has been disconnected from system with ignition in ACC or ON. Or, when this code was recorded, multi–display assembly was disconnected. 01 *3 (Communication Control) D8 No Response to Connection Check Component shown by auxiliary code is or had been disconnected from system after engine start. D9 01 *2 (Communication Control) D9 Last Mode Error Component operated (sounds and/ or images were provided) before engine stop is or has been disconnected with ignition switch in ACC or ON. 01 (Communication Control) DA No Response to ON/OFF Instruction 01 *2 (Communication Control) DB Mode Status Error 01 *4 (Communication Control) DC Transmission Error 01 *5 (Communication Control) DD Master Reset (Momentary Interruption) 2001 PRIUS (RM778U)
Check harness for power supply system of multi display.
Check harness for communication system of multi display.
Check harness for power supply system of radio receiver assembly.
Check harness for communication system of radio receiver assembly.
Check harness for power supply system of component shown by auxiliary code.
Check harness for communication system of component shown by auxiliary code. Check harness for power supply system of component shown by auxiliary code. Check harness for communication system of component shown by auxiliary code.
Check harness for power supply of component shown by auxiliary code.
Check harness for communication system of component shown by auxiliary code.
If error occurs again, replace component shown by auxiliary code. Dual alarm is detected.
Check harness for power supply of component shown by auxiliary code.
Check harness for communication system of component shown by auxiliary code. Transmission to component shown
If same auxiliary code is recorded by auxiliary code has been failed. in other component, check harness (Detecting this DTC does not nec- for power supply and communication system of components shown essary mean actual failure.) sub code. No response is identified when changing mode (audio and visual mode change). Detected when sound and picture does not change by button operation. After engine is started, multi–dis-
If this error occurs frequently, replay assembly was disconnected place multi–display assembly. from system. DI–816 DIAGNOSTICS – NAVIGATION SYSTEM After engine is started, slave com-
Check harness for power supply ponent was disconnected from sys- of component shown by auxiliary tem. code.
Check harness for communication system of component shown by auxiliary code. Due to defective condition of multi
Check harness for power supply display, master function is switched of multi–display assembly.
Check harness for communicato audio equipment. Error occurs in communication be- tion system of multi–display assemtween sub–master (audio) and mul- bly.
Check harness for communicati display. tion system between multi–display assembly and sub–master component. ”Registration Completion Instruc-
Since this DTC is provided for ention” command from multi display gineering purpose, it may be decannot be received. tected when no actual failure exists. 01 *5 (Communication Control) DE Slave Reset (Momentary Interruption) 01 *6 (Communication Control) DF Master Error 01 (Communication Control) E0 01 *2 (Communication Control) E1 Registration Completion Instruction Error Audio processor ON error 01 (Communication Control) E2 01 (Communication Control) E3 01 (Communication Control) E4 Plural Frame Abort 60 (Radio receiver assembly) 43 AM Tuner Error Abnormal condition is detected in Replace radio receiver assembly. AM tuner. Inspect radio receiver assembly. 60 (Radio receiver assembly) 44 FM Tuner Error Abnormal condition is detected in Replace radio receiver assembly. FM tuner. 61 (Cassette switch) 40 Mechanical or Media Error Malfunction due to mechanical fail- Inspect cassette tape. ure is identified. Or, cassette tape is cut or entangled. 61 (Cassette switch) 41 EJECT Malfunction Malfunction due to mechanical fail- Replace radio receiver assembly. ure. 62 (CD player) 62 (CD player) 42 No Disc Readout CD Error Disc cannot be read. Inspect CD. Error is detected in CD player. Replace radio receiver assembly. 44 2001 PRIUS (RM778U) ON/OFF Instruction Parameter Error Registration Request Transmission While source equipment is operat-
Check harness for power supply of multi–display assembly. ing, AMP output is stopped.
Check harness for communication system of multi–display assembly. Error occurs in ON/OFF controlling
Replace multi–display assembly. command from multi–display assembly. Registration Request command is output from slave component. Receiving Connection Check Instruction, Registration Request command is output from sub–master component. Plural frame transmission is aborted.
Since this DTC is provided for engineering purpose, it may be detected when no actual failure exists.
Since this DTC is provided for engineering purpose, it may be detected when no actual failure exists. DI–817 DIAGNOSTICS – NAVIGATION SYSTEM 62 (CD player) 45 EJECT Error 62 (CD player) 46 Scratched/ Scratches or dirt is found on CD sur- Inspect CD. Reversed Disc face or CD is set upside down. Magazine cannot be ejected. Replace radio receiver assembly. *2: Even if no failure is detected, it may be stored depending on the battery condition or voltage for starting an engine. *3: It is stored when 180 sec. has passed after the power supply connector is pulled out after engine start. *4: It may be stored when the engine key is turned again 1 min. after engine start. *5: It may be stored when the engine key is turned again after engine start. *6: When 210 sec. has passed after pulling out the power supply connector of the master component with the ignition switch in ACC or ON, this code is stored. Physical address: 178 Navigation ECU 58 10 (Navigation ECU) Error in gyro sensor is detected. (Abnormal value in voltage output from sensor is detected for more than specified time.) GPS Receiver Operation error of GPS receiver is Error detected.
Check the Gyro voltage in the diagnosis system mode.
Check if the GPS antenna is correctly connected or positioned or not. After replacing the antenna, if the error remains, replace the navigation ECU. Gyro Error
At an outdoor site with a clear view, operate to display the GPS information screen of the diagnosis system. If GPS time stamp is not properly displayed after 15 min. or more, replace navigation ECU. 58 (GPS receiver) 11 58 (GPS receiver) 40 GPS Antenna Operation condition of GPS antenError na cable is detected. (Open circuit, connection failure of connectors, etc.) 58 (GPS receiver) 41 Power Supply Abnormal voltage of GPS antenna
Inspect GPS antenna and replace Error of GPS cable or short circuit is detected. if necessary. (When no continuity is Antenna identified between connector’s core and sealed part, GPS antenna is normal.)
If GPS antenna is normal, replace navigation ECU. 58 42 (Navigation ECU) 58 43 (Navigation ECU) Map Disc Error Data cannot be read for a specified time due to scratches or dirt on disc surface or insertion of music CD. Vehicle speed Input error of vehicle speed sensor sensor Signal signal is detected. (When no vehicle Error speed sensor signal has been input for a specified time.)
Inspect disc and replace if necessary. (Visually check disc surface and wipe it with soft cloth.)
Check the vehicle speed signal in the diagnosis system mode.
Inspect wire harness for vehicle speed signal.
If wire harness is normal, replace navigation ECU. 58 44 (Navigation ECU) Player Error Malfunction of player continues for a
Check if disc can be inserted/takspecified length of time. en out or not. If not , replace navigation ECU.
When the same code is detected in recheck after deleting the DTC memory. 58 45 (Navigation ECU) Player Temp. Too High Readout cannot be done because With IG switch OFF, leave vehicle in temperature around player’s pickup cool shaded place for a while and (reading part) is too high. recheck. After deleting the DTC memory, If same code detected, replace navigation ECU. 2001 PRIUS (RM778U) DI–818 DIAGNOSTICS – NAVIGATION SYSTEM 01 (Communication Control) D6 Absence of Master Component in which this code is recorded has been disconnected from system with ignition in ACC or ON. Or, when this code was recorded, multi–display assembly was disconnected.
Check harness for power supply system of multi display.
Check harness for communication system of multi display.
Check harness for power supply system of navigation ECU.
Check harness for communication system of navigation ECU. 01 *6 (Communication Control) D7 Connection Check Error Component in which this code is recorded has been disconnected from system after engine start. Or, when this code was recorded, multi–display assembly was disconnected. D6
Check harness for power supply system of multi display.
Check harness for communication system of multi display.
Check harness for power supply system of navigation ECU.
Check harness for communication system of navigation ECU. 01 (Communication Control) DC Transmission Error Transmission to component shown by auxiliary code has been failed. (This code does not necessarily mean actual failure.) If same auxiliary code is recorded in other component(s), check harness for power supply and communication system of components shown sub code. 01 (Communication Control) DD Master Reset (Momentary Interruption) After engine is started, multi–dis-
Check harness for power supply play assembly was disconnected system of multi–display assembly. from system.
Check harness for communication system of multi–display assembly.
If error occurs frequently, replace multi–display assembly. 01 (Communication Control) DF Master Error Due to defective condition of component with a display, master function is switched to audio equipment . Error occurs in communication between sub–master (audio) and master component. 01 (Communication Control) E0 Registration Completion Instruction Error 01 (Communication Control) E2 ON/OFF Instruction Parameter Error Error is detected in ON/OFF control Replace multi–display assembly. command from multi–display assembly. 01 (Communication Control) E3 Registration Request Transmission
Registration Request command Since this DTC is provided for engiis output from slave component. neering, it may be detected when
By reception of connection check no actual failure exists. Instruction, Registration Request command is output from sub–master component. 01 (Communication Control) E4 Plural Frame Abort Plural frame transmission is aborted.
Check harness for power supply of multi–display assembly.
Check harness for communication system of multi–display assembly.
Check harness for communication system between multi–display assembly and sub–master component. ”Registration Completion Instruc- Since this DTC is provided for engition” command from multi display neering, it may be detected when cannot be received. no actual failure exists.
Since this DTC is provided for engineering purpose, it may be detected when no actual failure exists. *6: When 210 sec. has passed after pulling out the power supply connector of the master component with the ignition switch in ACC or ON, this code is stored. 2001 PRIUS (RM778U) DI–820 DIAGNOSTICS – NAVIGATION SYSTEM DI7OT–01 TERMINALS OF ECU MULTI DISPLAY M5 M7 M6 I15528 Problem symptom when open circuit is detected. Symbols (Terminals NO. ) C diti Condition STD Voltage V lt (V) Problem symptom when short circuit is detected. TX+ (M5–3) Ignition switch ACC or ON About 2.5 V Screen is in disorder. TX3+ (M5–4) Ignition switch ACC or ON About 2.5 V Screen is in disorder. SPD – GND (M5–5 – M7–6) Ignition switch ON, and driving wheel rotated slowly Repeatedly changes from below 1 to 9 V Fuel efficiency cannot be calculated. TX– (M5–10) Ignition switch ACC or ON About 2.5 V Screen is in disorder. TX3– (M5–11) Ignition switch ACC or ON About 2.5 V Screen is in disorder. PKB – GND (M5–13 – M7–6) Parking brake switch ON (parking brake lever released) 5V The system cannot enter Diagnosis System mode. TC – GND (M5–14 – M7–6) Ignition switch OFF and connect thermals TC and E1 of diagnosis check connector Continuity Navigation system is normal. VR – VG (M6–1 – M6–6) Constant Continuity Screen noise or other types of noise occur. R – VG (M6–2 – M6–6) Diagnosis display check screen is white (Using an oscilloscope) 0.7 V ± 0.1 V *2 Screen color turns to blue. B – VG (M6–3 – M6–6) Diagnosis display check screen is white (Using an oscilloscope) 0.7 V ± 0.1 V *2 Screen color turns to yellow. TX1+ (M6–5) AVC–LAN communication circuit – Navigation system does not operate. VG – GND (M6–6 – M7–6) Constant Continuity Screen noise or other types of noise occur. The system cannot exit Service Check mode. Navigation system does not operation. G – VG (M6–7 – M6–6) 2001 PRIUS (RM778U) Diagnosis display check screen is white (Using an oscilloscope) 0.7 V ± 0.1 V *2 Screen color turns to red–purple. DI–821 DIAGNOSTICS – NAVIGATION SYSTEM SYNC – VG (M6–8 – M6–6) Display ON (Using an oscilloscope) 0.5 V – 1.3 V *1 Screen is in disorder TX1– (M6–10) AVC–LAN communication circuit – Navigation system does not operate. +B1 – GND (M7–1 – M7–6) Constant 10 – 14 V Navigation system does not operate. IG – GND (M7–2 – M7–6) Ignition switch ON 10 – 14 V Navigation system does not operate. DR – GND (M7–3 – M7–6) Light control switch TAIL or HEAD and cover the top of automatic light control sensor 9 V or more No problem is identified in the display. ACC – GND (M7–4 – M7–6) Ignition switch ACC 10 – 14 V Navigation system does not operate. GND – Body ground (M7–6 – Body ground) Constant Below 1 V Audio system is normal. TAIL – GND (M7–8 – M7–6) Light control switch TAIL or HEAD 9 V or more Switching between Night and Day mode cannot be done. 2001 PRIUS (RM778U) DI–822 DIAGNOSTICS – NAVIGATION SYSTEM NAVIGATION ECU N2 N3 I15499 Problem symptom when open circuit is detected. Symbols (Terminals NO. ) C diti Condition STD Voltage V lt (V) Problem symptom when short circuit is detected. AUI+ – GND (N2–1 – N2–17) Radio switch ON 5–7V Driver’s side speaker does not sound. AUO+ – GND (N2–2 – N2–17) Radio switch ON 5–7V Driver’s side speaker does not sound. SPD – GND (N2–5 – N2–17) Ignition switch ON and driving wheel rotated slowly Repeatedly changes from below 1 to 9 V Navigation operation is available during, or a cursor on present site does not move. +B – GND (N2–9 – N2–17) Constant 10 – 14 V The set route can not be memorized. (The route disappears by turning the ignition switch OFF.) Fuse is blown. AUI– – GND (N2–10 – N2–17) Radio switch ON 5–7V Driver’s side speaker does not sound. AUO– – GND (N2–11 – N2–17) Radio switch ON 5–7V Driver’s side speaker does not sound. REV – GND (N2–14 – N2–17) A/T shift position R 5V GND – Body ground (N2–17 – Body ground) Constant Below 1 V Audio system is normal. ACC – GND (N2–18 – N2–17) Ignition switch ACC or ON 10 – 14 V Audio system does not sound. VR – VG (N3–1 – N3–6) Constant Continuity Screen noise or other types of noise occur. The direction of advance of the vehicle is different from that of the cursor. Navigation system does not operation. R – VG (N3–2 – N3–6) 2001 PRIUS (RM778U) Diagnosis display check screen is white (Using an oscilloscope) 0.7 V ± 0.1 V*1 Screen color turns to blue. DI–823 DIAGNOSTICS +B – GND (N3–3 – N2–17) – Constant NAVIGATION SYSTEM 10 – 14 V The set route can not be memorized. (The route disappears by turning the ignition switch OFF.) Fuse is blown. B – VG (N3–3 – N3–6) Diagnosis display check screen is white (Using an oscilloscope) 0.7 ± 0.1 V*2 Screen color turns to yellow. TX1+ – GND (N3–5 – N2–17) Ignition switch ACC or ON 2–3V Navigation system does not operate. VG – GND (N3–6 – N2–17) Constant Continuity Screen noise or other types of noise occur. Navigation system does not operation. G – VG (N3–7 – N3–6) Diagnosis display check screen is white (Using an oscilloscope) 0.7 ± 0.1 V*2 Screen color turns to red–purple. SYNC – VG (N3–8 – N3–6) Display ON (Using an oscilloscope) 0.5 − 1.3 V*1 Screen is in disorder. TX1– – GND (N3–10 – N2–17) Ignition switch ACC or ON 2–3V Navigation system does not operate. Oscilloscope *1: wave1 GND
Measure terminal: SYNC ↔ GND1
Measure set: 500 mV/DIV 10 µs/DIV
Condition: Navigation display is displayed I15531 *2: wave2 GND
Measure terminal: R, G, B ↔ GND1
Measure set: 200 mV/DIV 10 µs/DIV
Condition: Navigation map is switched I15532 2001 PRIUS (RM778U) DI–827 DIAGNOSTICS – NAVIGATION SYSTEM DI7OW–01 3. No navigation screen displayed when ”MAP”, ”Menu”, or ”DEST” switch pressed. (Screen cannot be switched.) INSPECTION PROCEDURE 1 Service check mode. (Check the navigation ECU) NG Troubleshoot for each diagnosis. OK Go to step 6. Ncon 2 Check the navigation ECU. PREPARATION: Disconnect the navigation ECU connector. CHECK: Check voltage terminals +B. OK: +B: 10 – 14 V CHECK: Check voltage terminal ACC when turn ignition switch ACC or ON position. OK: ACC: 10 – 14 V CHECK: Check continuity terminal GND. OK: GND: Continuity NG OK 2001 PRIUS (RM778U) Replace or repair wire harness or connector. DI–828 DIAGNOSTICS 3 – NAVIGATION SYSTEM Check the navigation ECU. CHECK: Check terminal R, G and B. OK: R, G, B: See ”Naavigation ECU” of ”TERMINAL OF ECU”. NG Replace the navigation ECU. OK 4 Check the multi display. PREPARATION: Disconnect the multi display connector. CHECK: Check voltage terminals +B. OK: +B: 10 – 14 V CHECK: Check voltage terminal ACC when turn ignition switch ACC or ON position. OK: ACC: 10 – 14 V CHECK: Check continuity terminal GND. OK: GND: Continuity NG Replace or repair wire harness or connector. OK 5 Check the multi display. CHECK: Check terminal R, G and B. OK: R, G, B: See ”multi display” of ”TERMINAL OF ECU”. NG OK 2001 PRIUS (RM778U) Replace the multi display. DI–829 DIAGNOSTICS – NAVIGATION SYSTEM Replace the multi display. 6 All of the switches (MAP, Menu, DEST etc.) does not function. No Replace the center cluster module control. Yes 7 Check each switch (A/C switch e.t.c.) of the center cluster module control does not function. No Yes Replace the multi display. 2001 PRIUS (RM778U) Replace the center cluster module control. DI–831 DIAGNOSTICS – NAVIGATION SYSTEM DI7OY–01 5. No navigation displayed, ”Audio OFF” on audio screen and no audio sound. INSPECTION PROCEDURE 1 Service check mode. NG Troubleshoot for each diagnosis. OK 2 Check the radio receiver assembly. PREPARATION: Disconnect the radio receiver assembly connector. CHECK: Check voltage terminals +B. OK: +B: 10 – 14 V CHECK: Check voltage terminal ACC when turn ignition switch ACC or ON position. OK: ACC: 10 – 14 V CHECK: Check continuity terminal GND. OK: GND: Continuity NG Replace or repair wire harness. OK 3 Check ”AVC–LAN communication circuit” (See page DI–860). NG OK 2001 PRIUS (RM778U) Replace the AVC–LAN circuit or radio receiver assembly. DI–832 DIAGNOSTICS Replace the multi display. 2001 PRIUS (RM778U) – NAVIGATION SYSTEM DI–833 DIAGNOSTICS – NAVIGATION SYSTEM DI7OZ–01 6. Screen cannot be dimmed in night time. INSPECTION PROCEDURE 1 Check if the screen is dimmed at night. (With the light control switch ON), do all screens except the navigation screen appear in Night Mode?) NG Check the light control switch. OK 2 Check the multi display. CHECK: Check terminal TAIL. OK: TAIL: See ”Multi display” of ”TERMINAL OF ECU”. NG Replace or repair wire harness. OK 3 Check the multi display. PREPARATION: Disconnect the multi display connector. CHECK: Check voltage terminals +B. OK: +B: 10 – 14 V CHECK: Check voltage terminal ACC when turn ignition switch ACC or ON position. OK: ACC: 10 – 14 V CHECK: Check continuity terminal GND. OK: GND: Continuity NG 2001 PRIUS (RM778U) Replace or repair wire harness. DI–834 DIAGNOSTICS OK Replace the multi display. 2001 PRIUS (RM778U) – NAVIGATION SYSTEM DI–836 DIAGNOSTICS – NAVIGATION SYSTEM DI7P1–01 8. Color on navigation screen is unusual (RGB signal error). INSPECTION PROCEDURE 1 Display check mode (Color bar check). NG 2 Replace the multi display. Navigation check mode (Color bar check). NG Go to step 4. OK 3 Check the screen setting. (Day or Night mode) OK Normal. NG 4 Check the navigation ECU. CHECK: Check terminals +B. OK: +B: 10 – 14 V CHECK: Check terminal ACC when turn ignition switch ACC or ON position. OK: ACC: 10 – 14 V CHECK: Check terminal R, G, B, VR or VG. OK: R, G, B, VR or VG: See ”Navigation ECU” of ”TERMINAL OF ECU” NG 2001 PRIUS (RM778U) Replace the wire harness when all terminals are faulty. Replace the wire harness when SYNC terminal is faulty. DI–837 DIAGNOSTICS OK Replace the multi display. 2001 PRIUS (RM778U) – NAVIGATION SYSTEM DI–840 DIAGNOSTICS – NAVIGATION SYSTEM DI7P4–01 11. No sound (radio, cassette tape, CD) can be heard from driver side door speaker only. INSPECTION PROCEDURE 1 Service check mode. NG Troubleshoot for each diagnosis. OK 2 Check wire harness (between navigation ECU and radio receiver assembly). PREPARATION: Disconnect the navigation ECU and radio receiver assembly connector. CHECK: (a) Check continuity between terminal AUI+ of navigation ECU connector and terminal FL+ of radio receiver assembly. (b) Check continuity between terminal AUI– of navigation ECU connector and terminal FL– of radio receiver assembly. OK: Continuity NG Replace or repair wire harness. OK 3 Check the navigation system voice. OK NG 2001 PRIUS (RM778U) Go to step 6. DI–841 DIAGNOSTICS 4 – NAVIGATION SYSTEM Check wire harness (between navigation ECU and driver side door speaker). PREPARATION: Disconnect the navigation ECU and driver side door speaker connector. CHECK: (a) Check continuity between terminal AUO+ of navigation ECU connector and terminal 1 of driver side door speaker. (b) Check continuity between terminal AUO– of navigation ECU connector and terminal 2 of driver side door speaker. OK: Continuity NG Replace or repair wire harness. OK 5 Check the driver side door speaker. NG Replace the speaker. OK Replace the navigation ECU. 6 Check the navigation ECU. CHECK: Check terminal AUO+, AUO–, AUI+ and AUI–. OK: AUO+, AUO–, AUI+ and AUI–: See ”Navigation ECU” of ”TERMINAL OF ECU”. NG OK Replace the radio receiver assembly. 2001 PRIUS (RM778U) Replace the navigation ECU. DI–842 DIAGNOSTICS – NAVIGATION SYSTEM DI7P5–01 12. Map DISC cannot be inserted. INSPECTION PROCEDURE 1 Check the MAP DISC. NG Replace the MAP DISC. OK Normal. OK 2 Insert a MAP DISC without tilt. NG 3 Check the navigation ECU. PREPARATION: Disconnect the navigation ECU connector. CHECK: Check voltage terminals +B. OK: +B: 10 – 14 V CHECK: Check voltage terminal ACC when turn ignition switch ACC or ON position. OK: ACC: 10 – 14 V CHECK: Check continuity terminal GND. OK: GND: Continuity NG OK 2001 PRIUS (RM778U) Replace or repair wire harness. DI–843 DIAGNOSTICS Replace the navigation ECU. 2001 PRIUS (RM778U) – NAVIGATION SYSTEM DI–846 DIAGNOSTICS – NAVIGATION SYSTEM DI7P8–01 15. Navigation screen cannot change to the night mode color. INSPECTION PROCEDURE 1 Check the setting. (Is it set to Day Mode in screen adjustment?) Yes Normal. No 2 Check if the screen is dimmed at night. (With the light control switch ON, do all screens except the navigation screen appear in Night Mode?) NG Go to step 5. OK 3 Does the beep sound by operating switches on the navigation screen? OK Replace the navigation ECU. NG 4 Check ”AVC–LAN communication circuit” (See page DI–860). NG OK Replace the navigation ECU. 2001 PRIUS (RM778U) Replace or repair AVC–LAN circuit. DI–847 DIAGNOSTICS 5 – NAVIGATION SYSTEM Check the multi display. CHECK: Check terminal TAIL. OK: TAIL: See ”Multi Display” of ”TERMINAL OF ECU”. OK NG Replace or repair wire harness. 2001 PRIUS (RM778U) Replace the multi display. DI–849 DIAGNOSTICS – NAVIGATION SYSTEM DI7PA–01 17. Vehicle position is deviated from correct point badly. INSPECTION PROCEDURE 1 Check the mark display. (At a place with a fine view, is GPS mark displayed or not?) No Go to step 7. Yes 2 Does the trouble occur in the specific area or not? Yes Normal. (If the vehicle is positioned in the place where it is difficult to be identified, the current vehicle position may be incorrectly displayed.) No 3 Check the setting (Color of the automatic calibration button on the calibration screen). Green Normal. (Drive the vehicle (10 km or more) until calibration is completed. Blue 4 Service check mode. (Is ”58–43” displayed in the unit check mode of the navigation ECU?) Yes No 2001 PRIUS (RM778U) Troubleshoot for each diagnosis. DI–850 DIAGNOSTICS 5 – NAVIGATION SYSTEM Navigation check mode (vehicle signal check mode: SPD). NG Replace or repair speed sensor wire harness. OK 6 Recurrence Test (Confirm the phenomenon) (Correct the current position and drive the vehicle for a while with the GPS mark displayed). OK Normal. NG Replace the navigation ECU. 7 Check if the harness is caught or sharply bent or not. NG Navigation antenna is surely connected. OK 8 Check optional components. (Does it become if the optionals such as the theft deterrent system is removed?) Yes Remove or change the position of the components. HINT: Some optionals receive radio signals, and if this happens, GPS reception may be affected. No 2001 PRIUS (RM778U) DI–851 DIAGNOSTICS 9 – NAVIGATION SYSTEM Is there anything such as a film stuck to the window? Yes Reception may be affected by a screen such as a film. No 10 Service check mode. (Is ”80–40, 41” is displayed in the unit check mode of the navigation ECU?) Yes No Replace the navigation antenna. HINT: If the trouble still occurs, replace the navigation ECU. 2001 PRIUS (RM778U) Troubleshoot for each diagnosis. DI–852 DIAGNOSTICS – NAVIGATION SYSTEM DI7PB–01 18. GPS mark does not appear. INSPECTION PROCEDURE 1 Check the mark display. (At a place with a fine view, is GPS mark displayed or not?) Yes Normal. No 2 Check if the harness is caught or sharply bent or not. NG Navigation antenna is surely connected. OK 3 Check optional components. (Does it become normal if the optionals such as the theft deterrent system is removed?) Yes Remove or change the position of the components. HINT: Some optionals receive radio signals, and if this happens, GPS reception may be affected. No 2001 PRIUS (RM778U) DI–853 DIAGNOSTICS 4 – NAVIGATION SYSTEM Is there anything such as a film stuck to the window? Yes Reception may be affected by a screen such as a film. No 5 Service check mode. (Is ”80–40, 41” is displayed in the unit check mode of the navigation ECU?) Yes No Replace the navigation antenna. HINT: If the trouble still occurs, replace the navigation ECU. 2001 PRIUS (RM778U) Troubleshoot for each diagnosis. DI–855 DIAGNOSTICS – NAVIGATION SYSTEM DI7PD–01 20. Vehicle position rotates without control. (Map rotates without control) INSPECTION PROCEDURE 1 Recheck. (While not rotating the vehicle, turn the ignition switch ON from OFF again.) OK Normal. (While the vehicle was turning, the ignition switch was turned ON.) NG 2 System check mode. (Is ”58–10” is displayed in the unit check mode of the navigation ECU?) Yes Replace the navigation ECU. No 3 System check mode. (Is ”58–43” is displayed in the unit check mode of the navigation ECU?) Yes Replace and repair SPD terminal wire harness. No 4 Navigation check mode (vehicle signal check mode: SPD and gyro). OK NG 2001 PRIUS (RM778U) Replace the navigation ECU. DI–856 DIAGNOSTICS Replace or repair wire harness. 2001 PRIUS (RM778U) – NAVIGATION SYSTEM DI–863 DIAGNOSTICS – NAVIGATION SYSTEM DI7PK–01 27. No AM, FM or CD screen is displayed. INSPECTION PROCEDURE 1 Check the sound. (Check if the sound of the radio, cassette or CD can be heard.) OK System check mode. (Check radio receiver assembly) NG 2 Check the radio receiver assembly. PREPARATION: Disconnect the radio receiver assembly connector. CHECK: Check voltage terminals +B. OK: +B: 10 – 14 V CHECK: Check voltage terminal ACC when turn ignition switch ACC or ON position. OK: ACC: 10 – 14 V CHECK: Check continuity terminal GND. OK: GND: Continuity NG OK 2001 PRIUS (RM778U) Replace or repair wire harness. DI–864 DIAGNOSTICS 3 – NAVIGATION SYSTEM Check ”AVC–LAN communication circuit” (See page DI–860). NG OK Replace the radio receiver assembly. 2001 PRIUS (RM778U) Replace or repair AVC–LAN circuit. DI–865 DIAGNOSTICS – NAVIGATION SYSTEM DI7PL–01 AVC–LAN (Communication bus) Circuit CIRCUIT DESCRIPTION Each unit of navigation system connected with AVC–LAN (communication bus) transfers the signal of each switch by communication. When +B short and GND short occur in this AVC–LAN, navigation system will not function normally as the communication is discontinued. In this AVC–LAN, multi display becomes the master of the communication, and the radio receiver assembly has a terminator necessary for transmitting the communication. multi display is connected between navigation ECU and radio receiver assembly, navigation system has the structure that makes communication impossible without navigation ECU, multi display or radio receiver assembly. AVC–LAN Radio Receiver Assembly Multi Display Navigation ECU Terminator I11572 2001 PRIUS (RM778U) DI–866 DIAGNOSTICS – NAVIGATION SYSTEM WIRING DIAGRAM AVC–LAN circuit Multi Display TX1– TX1+ TX– TX+ Navigation ECU 10 M6 G 7 IJ1 G 10 N3 TX1– 5 M6 R 6 IJ1 R 5 N3 TX1+ 10 M5 G 3 M5 R F14 Front Door Speaker LH C7 Center Cluster SW C TX+ TX– 1 2 P 3 IG1 G 6 IJ2 G 2 N2 AUO+ V 4 IG1 R 7 IJ2 R 11 N2 AUO– V 10 N2 AUI– P 1 N2 AUI+ F R 7 C R 10 6 R4 TX+ FL– R3 V G 9 2 R4 TX– FL+ R3 P C G 8 F F 9 IJ2 8 IJ2 J26 J/C Radio receiver assembly I15473 2001 PRIUS (RM778U) DI–867 DIAGNOSTICS – NAVIGATION SYSTEM INSPECTION PROCEDURE 1 Check wire harness and connector between radio receiver assembly and navigation ECU (See page IN–41). NG Repair or replace wire harness or connector between radio receiver assembly and navigation ECU. OK 2 Check wire harness and connector between multi display and navigation ECU (See page IN–41). NG OK 2001 PRIUS (RM778U) Repair or replace wire harness or connector between multi display and navigation ECU. DI–868 DIAGNOSTICS 3 – NAVIGATION SYSTEM Skip radio receiver assembly and check AVC–LAN. Multi Display Radio Receiver Assembly Navigation ECU TX+ TX– Radio receiver assembly connector ”R4” TX+ TX– SST PREPARATION: (a) Connect Multi Display connector. (b) Disconnect radio receiver assembly ”R4” connector. (c) Using SST (Navigation Check Wire P/N 09843–18050), connect the terminal TX+ to terminal TX– of ”R4” connector of radio receiver assembly. CHECK: Operate the panel switch and the touch switch of the display and check that the navigation functions. (Check that AVC–LAN is recovered.) I12172 OK NG Replace the Navigation ECU. 2001 PRIUS (RM778U) Replace the radio receiver assembly. DI–871 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7S1–01 PRE–CHECK 0.5 Seconds 1. WARNING FOR A/C COMPRESSOR LOCK If compressor lock occurs during A/C operation, the A/C switch indicator on the A/C control assembly starts blinking. When this occurs, check for compressor lock (DTC 22) using diagnosis trouble code check then proceed to inspect the circuit or the component. Compressor lock sensor circuit. → (See page DI–891) ON OFF 0.5 Seconds AT0716 2. LIST OF OPERATION METHODS By operating each of the A/C control switches as shown in the diagram below, it is possible to enter the diagnosis check mode. With in 5 sec. after turning the ignition on, press the A/C switch 3 times and turn the blower switch from OFF to AUTO. If both A/C switch and blower switch are not operated. Indicator check (See step 3) Actuator check (See step 5) After indicators blink 4 times Auto DTC check (See step 4) Actuator check (See step 5) Except Auto Auto Except Auto Cancel check mode and can start A/C control. : Indicates a blower switch operation 2001 PRIUS (RM778U) DI–872 DIAGNOSTICS A/C Switch Blower Switch – AIR CONDITIONING SYSTEM 3. (a) INDICATOR CHECK Within 5 sec. after turning the ignition switch on, press the A/C switch 3 times and turn the blower switch from OFF to AUTO. (b) Check that all the indicators light up and go off at 1 second intervals 4 times in succession. I18151 Blinking Pattern 4 times 1 sec. HINT:
1 sec. ON
OFF After the indicator check is ended, the system enters the DTC begins automatically. Operate the blower switch from AUTO to except AUTO position when desiring to cancel the check mode. I00339 4. (a) No Malfunction 1 sec. 0.5 sec. (b) ON HINT: The illustration shows the blinking pattern associated with the DTC 12 and 23. If 2 or more DTCs (abnormalities) are indicated, the lowest number (code) is output first. (c) Identify the problem using the chart of the DTC. OFF Malfunction Detected 0.5 sec. 1.5 sec 2.5 sec. 1.5 sec. ON OFF 2001 PRIUS (RM778U) DTC CHECK (SENSOR CHECK) Perform an indicator check. After the indicator check is completed, the system enters the DTC check mode automatically. Read the DTC as indicated by the number of blinks of the A/C indicator. 4.5 sec. ← → Repeat DI–873 DIAGNOSTICS 5. (a) (b) 21.0 ↔ 23.5 (67 ↔ 72) → 3 24.0 ↔ 26.0 (73 ↔ 77) 17 4 26.5 ↔ 29.0 (78 ↔ 83) 5 29.5 (84) ↔ Max. Warm 31 2001 PRIUS (RM778U) Air Inlet Damper Air Outlet Compressor Damper –10 % (Cool) REC (–1 %) FACE (–10 %) R/F (82.0 %) B/L (15 %) → 2 4 Air Mix Damper R/F (102.0 %) FOOT (50 %) OFF FRS (110.0 %) DEF (110 %) → Max. Cool ↔ 20.5 (66) HINT: To cancel the check mode, turn blower switch from AUTO to except AUTO. FRS (110.0 %) F/D (90 %) → 1 → Step Temp. setting Blower Level °C (°F) No. ACTUATOR CHECK Actuator check mode is started at the same time with DTC check mode. Check visually on by hand that the air flow, amount of damper operating and operation of the compressor changes according to the set temperature of the A/C control panel, as shown in the chart. → I18151 AIR CONDITIONING SYSTEM 50 % (Cool/Warm) → Blower Switch – 100 % (Warm) ON DI–874 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7S2–01 DIAGNOSTIC TROUBLE CODE CHART DTC No. (See Page) Detection Item Trouble Area Room temp. sensor circuit
Room temp. sensor
Harness or connector between room temp. sensor and A/C amplifier
A/C amplifier Ambient temp. sensor circuit
Ambient temp. sensor
Harness and connector between ambient temp. sensor and ECM
ECM
Harness and connector between ECM and A/C amplifier
A/C amplifier Evaporator temp. sensor circuit
Evaporator temp. sensor
Harness and connector between evaporator temp. sensor and A/C amplifier
A/C amplifier Engine coolant temp. sensor circuit
Water temp. sensor
Harness and connector between engine coolant temp. sensor and ECM
ECM
Harness and connector between ECM and A/C amplifier 21*3 (DI–888) Solar sensor circuit
Solar sensor
Harness or connector between room temp. sensor and A/C amplifier
A/C amplifier 22*4 (DI–891) All conditions below are detected for 3 sec. or more (g) Engine speed: 500 rpm or more (h) Ratio between engine and compressor rpm deviates 20 % or more in comparison to normal operation
Compressor drive belt
Compressor lock sensor
Compressor
Harness and connector between compressor lock sensor and A/C amplifier 23 (DI–894) Open in pressure switch circuit Abnormal refrigerant pressure [below 196 kPa (2.0 kgf/cm2, 28 psi) over 3,140 kPa (32.0 kgf/cm2, 455 psi)]
Pressure switch
Harness or connector between pressure switch and A/C amplifier
A/C amplifier Air mix damper position sensor circuit
Air mix control servomotor
Harness or connector between air mix control servomotor and A/C amplifier
A/C amplifier Air inlet damper position sensor circuit
Air inlet control servomotor
Harness or connector between air inlet control servomotor and A/C amplifier
A/C amplifier Air outlet damper position sensor circuit
Air outlet control servomotor
Harness or connector between air outlet control servomotor and A/C amplifier
A/C amplifier Air mix control servomotor circuit
Air mix control servomotor
Air mix damper position sensor
Harness or connector between air mix control servomotor and A/C amplifier
A/C amplifier 11*1 (DI–876) 12*2 (DI–879) 13 (DI–882) 14 (DI–885) 31 (DI–897) 32 (DI–900) 33 (DI–903) 41 (DI–906) 2001 PRIUS (RM778U) DI–875 DIAGNOSTICS 42 (DI–909) 43 (DI–912) – AIR CONDITIONING SYSTEM Air inlet control servomotor circuit
Air inlet control servomotor
Air inlet damper position sensor
Harness or connector between air inlet control servomotor and A/C amplifier
A/C amplifier Air outlet control servomotor circuit
Air outlet control servomotor
Air outlet damper position sensor
Harness or connector between air outlet control servomotor and A/C amplifier
A/C amplifier HINT:



*1: If the room temp. is approx. –18.6°C (–3.7°F) or lower, trouble code 11 may be output even though the system is normal. *2: If the ambient temp. is approx. –52.9°C (–61.4°F) or lower, a malfunction code may be output even though the system is normal. *3: If the check is being performed in a dark place, DTC 21 (solar sensor circuit abnormal) could be displayed. *4: To confirm DTC 22, perform the following steps. (1) With the engine is running, enter the DTC check mode. (2) Enter actuator check mode and set the operation to step NO. 1. (3) Check that the DTC 22 is output. 2001 PRIUS (RM778U) DI–876 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7S4–01 TERMINALS OF ECU A9 A8 A7 I18176 Symbols (Terminals No.) Wiring Color Condition STD Voltage (V) IG ↔GND (A7–1 ↔ A7–7) R ↔ W–B IG ON. BLW ↔ GND (A7–3 ↔ A7–7) V ↔ W–B IG ON. Blower motor: Operate Pulse generation MP2+ ↔ GND (A7–4 ↔ A7–7) GR–B ↔ W–B IG ON. Pulse generation GND ↔ Body ground (A7–7 ↔ Body ground) W–B ↔ Body ground Always Continuity +B ↔ GND (A7–8 ↔ A7–7) R–G ↔ W–B Always 10 – 14 IG ON. Head lamp: ON Rear defogger: ON Set temp.: MAX. HOT 10 – 14 IG ON. Head lamp: OFF Rear defogger: OFF Below 1.0 IDH ↔ GND (A8–10 ↔ A7–7) Y ↔ W–B MPX+ ↔ GND (A7–11 ↔ A7–7) RF ↔ GND (A8–1 ↔ A7–7) CF ↔ GND (A8–2 ↔ A7–7) WP ↔ GND (A8–3 ↔ A7–7) GR ↔ W–B R W ↔ W–B R–W W B V Y ↔ W–B V–Y W B L R ↔ W–B L–R W B IG ON. Start engine. Water temp.: Below 90°C Refrigerant pressure: Below 1,520 kPa 10 – 14 Pulse generation 10 – 14 Start engine. Water temp.: Approx. 90°C Refrigerant pressure: Above 1,520 kPa Below 1.0 Start engine. A/C compressor: ON Below 1.0 Start engine. A/C compressor: OFF 10 – 14 Engine speed: Above 500 rpm Blower motor: Operate Below 1.0 Engine speed: Above 500 rpm Blower motor: Not operate 10 – 14 NE ↔ GND (A8–4 ↔ A7–7) LG ↔ W–B ACT ↔ GND (A8–5 ↔ A7–7) P–G ↔ W–B Engine speed: Idle speed 10 – 14 P–B ↔ W–B Start engine Head lamp: OFF Rear defogger: OFF Set temp.: MAX. WARM Blower mode dial: HI Mode selector: F/D Water temp.: Below 55 °C Below 0.7 HTR0 ↔ GND (A8–6 ↔ A7–7) 2001 PRIUS (RM778U) Start engine Pulse generation DI–877 DIAGNOSTICS LOCk ↔ SGLOCK (A8–9 ↔ A7–18) W–L ↔ BR–W MGC ↔ GND (A8–11 ↔ A7–7) LG R ↔ W–B LG–R W B PSW ↔ GND (A8–11 ↔ A7–7) L–Y ↔ W–B HTR2 ↔ GND (A8–13 ↔ A7–7) P ↔ W–B SGLOCK ↔ GND (A8–18 ↔ A7–7) BR–W ↔ W–B – AIR CONDITIONING SYSTEM Start engine. A/C compressor ON. Pulse generation Start engine. A/C compressor: ON Below 1.0 Start engine. A/C compressor: OFF A/C refrigerant pressure: less than 0.19 Mpa (2.0 more than 3.14 Mpa (3,140 kgf/cm2) 10 – 14 kgf/cm2) or From 10 – 14 to Below 1.0 Start engine Head lamp: OFF Rear defogger: OFF Set temp.: MAX. WARM Blower mode dial: HI Mode selector: F/D Water temp.: 55 – 70°C Below 0.7 Always Continuity IG ON. Ambient temp. 25°C (77°F) 1.35 – 1.75 IG ON. Ambient temp. 40°C (104°F) 0.85 – 1.25 TE ↔ SGTE (A9–1 ↔ A9–2) W↔W SGTE ↔ GND (A9–2 ↔ A7–7) W ↔ W–B Always Continuity SGTR ↔ GND (A9–3 ↔ A7–7) W ↔ W–B Always Continuity TR ↔ SGTR (A9–4 ↔ A9–3) W↔W IG ON. Room temp. 25°C (77°F) 1.8 – 2.2 IG ON. Room temp. 40°C (104°F) 1.2 – 1.6 TS ↔ S5TS (A9–5 ↔ A9–6) W↔W S5TS ↔ GND (A9–6 ↔ A7–7) IG ON. Solar sensor subject to electric light 1.0 or more IG ON. Solar sensor cover by a cloth Below 1.0 W ↔ W–B IG ON. 4.5 – 5.5 S5TPM ↔ SGTPM (A9–7 ↔ A9–9) W↔W IG ON. 4.5 – 5.5 TPM ↔ SGTPM (A9–8 ↔ A9–9) W↔W IG ON. Mode selector: FACE Below 1.0 IG ON. Mode selector: DEF 4.5 – 5.5 SGTPM ↔ GND (A9–9 ↔ A7–7) W ↔ W–B Always Continuity AOF ↔ GND (A9–10 ↔ A7–7) W ↔ W–B W B AOD ↔ GND (A9–11 ↔ A7–7) W ↔ W–B W B AMH ↔ GND (A9–13 ↔ A7–7) W ↔ W–B W B AMC ↔ GND (A9–14 ↔ A7–7) W↔W SGTP ↔ GND (A9–15 ↔ A7–7) W ↔ W–B TP ↔ SGTP (A9–16 ↔ A9–15) W↔W S5TP ↔ SGTP (A9–17 ↔ A9–15) S5TPI ↔ SGTPI (A9–18 ↔ A9–20) 2001 PRIUS (RM778U) IG ON. Mode selector: FACE 10 – 14 IG ON. Mode selector: DEF Below 1.0 IG ON. Mode selector: FACE Below 1.0 IG ON. Mode selector: DEF 10 – 14 IG ON. Set temp.: Max. COOL 10 – 14 IG ON. Set temp.: Max. WARM Below 1.0 IG ON. Set temp.: Max. COOL Below 1.0 IG ON. Set temp.: Max. WARM 10 – 14 Always Continuity IG ON. Set temp.: Max. COOL Below 1.0 IG ON. Set temp.: Max. WARM 4.5 – 5.5 W↔W IG ON. 4.5 – 5.5 W↔W IG ON. 4.5 – 5.5 DI–878 DIAGNOSTICS TPI ↔ SGTPI (A9–19 ↔ A9–20) W↔W SGTPI ↔ GND (A9–20 ↔ A7–7) W ↔ W–B AIR ↔ GND (A9–21 ↔ A7–7) W ↔ W–B W B AIF ↔ GND (A9–22 ↔ A7–7) W ↔ W–B W B 2001 PRIUS (RM778U) – AIR CONDITIONING SYSTEM IG ON. Air intake selector: FRESH Below 1.0 IG ON. Air intake selector: RECIRCULATE 4.5 – 5.5 Always Continuity IG ON. Air intake selector: FRESH Below 1.0 IG ON. Air intake selector: RECIRCULATE 10 – 14 IG ON. Air intake selector: FRESH 10 – 14 IG ON. Air intake selector: RECIRCULATE Below 1.0 DI–879 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7S3–01 PROBLEM SYMPTOMS TABLE Symptom Suspect Area See page Whole function of the does not operate 3. A/C amplifier 4. IG power source circuit IN–41 DI–916 Air Flow Control: No blower operation 1. 2. 3. 4. IG power source circuit Heater main relay circuit Blower motor circuit A/C amplifier DI–916 DI–921 DI–924 IN–41 Air Flow Control: No blower control 1. Heater main relay circuit 2. Blower motor circuit 3. A/C amplifier DI–921 DI–924 IN–41 Air Flow Control: Insufficient air flow 1. Blower motor circuit DI–924 Temperature Control: No cool air comes out 1. Refrigerant volume 2. Drive belt tension 3. Refrigeration system inspection with manifold gauge set 4. Compressor circuit 5. Pressure switch circuit 6. Compressor lock sensor circuit 7. Air mix damper position sensor circuit 8. Air mix damper control servomotor circuit 9. Room temperature sensor circuit 10.Ambient temperature sensor circuit 11.A/C amplifier AC–3 AC–15 AC–3 DI–927 DI–894 DI–891 DI–897 DI–906 DI–874 DI–879 IN–41 1. 2. 3. 4. Air mix damper position sensor circuit Air mix damper control servomotor circuit DC/DC converter circuit PTC heater circuit 5. 6. 7. 8. Room temperature sensor circuit Ambient temperature sensor circuit Evaporator temperature sensor circuit A/C amplifier DI–897 DI–906 DI–934 DI–937, DI–942 DI–876 DI–882 DI–885 IN–41 Temperature Control: No warm air comes out Temperature Control: Output air is warmer or cooler that the set temperature or response is slow 1. Refrigerant volume 2. Drive belt tension 3. Refrigeration system inspection with manifold gauge set 4. Radiator fan and condenser fan circuit 5. Solar sensor circuit 6. Room temperature sensor circuit 7. Ambient temperature sensor circuit 8. Evaporator temperature sensor circuit 9. Air mix damper position sensor circuit 10.Air mix damper control servomotor circuit 11.Evaporator 12.Heater radiator 13.Expansion valve 14.A/C amplifier AC–3 AC–15 AC–3 DI–947 DI–888 DI–876 DI–879 DI–885 DI–897 DI–906 AC–28 AC–28 AC–52 IN–41 Temperature Control: No temperature control (only Max. cool or Max. warm) 1. 2. 3. 4. 5. Room temperature sensor circuit Ambient temperature sensor circuit Air mix damper position sensor circuit Air mix damper control servomotor circuit A/C amplifier DI–876 DI–882 DI–897 DI–906 IN–41 No air inlet control 1. Air inlet damper position sensor circuit 2. Air inlet damper control servomotor circuit 3. A/C amplifier DI–900 DI–909 IN–41 2001 PRIUS (RM778U) DI–880 DIAGNOSTICS – AIR CONDITIONING SYSTEM Engine idle up does not occur, or is continuous 1. Compressor circuit 2. A/C amplifier DI–927 IN–41 Blinking of A/C indicator 1. Compressor lock sensor circuit 2. A/C amplifier DI–891 IN–41 2001 PRIUS (RM778U) DI–881 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7S5–01 CIRCUIT INSPECTION DTC 11 Room Temperature Sensor Circuit CIRCUIT DESCRIPTION This sensor detects the temperature inside the cabin and sends the appropriate signals to the A/C amplifier. DTC No. 11 Detection Item Trouble Area
Room temperature sensor.
Harness or connector between room temp. sensor and A/C amplifier. amplifier
A/C amplifier. Open or short in room temperature sensor circuit. WIRING DIAGRAM A/C Amplifier W 3 A9 SGTR W 4 A9 TR 2 A11 A/C Room Temp. Sensor 1 I18376 2001 PRIUS (RM778U) DI–882 DIAGNOSTICS – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminals TR and SGTR of A/C amplifier connector. ON TR SGTR (+) (–) I18162 PREPARATION: (a) Remove center cluster module control with connectors still connected. (b) Turn the ignition switch ON. CHECK: Check voltage between terminals TR and SGTR of A/C amplifier connector at each temperature. OK: at 25 °C (77 °F) : 1.8 – 2.2 V at 40 °C (104 °F) : 1.2 – 1.6 V HINT: As the temperature increases, the voltage decreases. NG Go to step 2. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–874). However, if DTC 11 is output, check and replace A/C amplifier. 2 Check room temperature sensor. I00317 PREPARATION: Remove room temperature sensor (See page AC–60). CHECK: Check resistance between terminals 1 and 2 of room temperature sensor connector at each temperature. OK: at 25 °C (77 °F) : 1.6 – 1.8 kΩ at 40 °C (104 °F) : 0.5 – 1.7 kΩ HINT: As the temperature increases, the resistance decreases. NG OK 2001 PRIUS (RM778U) Replace room temperature sensor. DI–883 DIAGNOSTICS 3 – AIR CONDITIONING SYSTEM Check harness and connector between A/C amplifier and room temperature sensor (See page IN–41). NG OK Check and replace A/C amplifier. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–884 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7S6–01 DTC 12 Ambient Temperature Sensor Circuit CIRCUIT DESCRIPTION This sensor detects the ambient temperature and sends the appropriate signals to the A/C amplifier. DTC No. 12 Detection Item Trouble Area
Ambient temperature sensor
Harness or connector between ambient tem temperature erature sensor and ECM
ECM
Harness or connector between ECM and A/C amplifier
A/C amplifier. Open or short in ambient temperature sensor circuit WIRING DIAGRAM Body ECU MPX+ 15 B8 GR–B A/C amplifier Combination Meter 2 3 MPX+ C11 MPX– C11 GR 1 A7 MPX+ 4 A7 MP2+ G1 Gateway ECU 11 G1 GR–L 2MPD 1MPD ECM 14 E10 1MPX TAM 4 G1 23 E8 GR–B W–G 5 IA2 W–G 2 A7 Ambient Temp. Sensor MPX– 16 B8 GR 13 E10 2MPX E2 18 E8 BR 2 IK1 1 BR–W I18377 2001 PRIUS (RM778U) DI–885 DIAGNOSTICS – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminals TAM and E2 of ECM connector. ON TAM ECM terminals (+) E2 (–) I18175 PREPARATION: (a) Remove ECM with connectors still connected. (b) Turn ignition switch ON. CHECK: Check voltage between terminals TAM and E2 of ECM connector at each temperature . OK: Voltage at 25 °C (77 °F) : 1.35 – 1.75 V at 40 °C (104 °F) : 0.85 – 1.25 V HINT: As the temperature increases, the voltage decreases. NG Go to step 2. OK Proceed to the next circuit inspection shown on problem symptoms table (See page DI–874). However, if DTC 12 is displayed, check and replace A/C amplifier. 2001 PRIUS (RM778U) DI–886 DIAGNOSTICS 2 – AIR CONDITIONING SYSTEM Check ambient temperature sensor. 2 PREPARATION: Disconnect ambient temperature sensor connector. CHECK: Check resistance between terminals 1 and 2 of ambient temperature sensor connector at each temperature. OK: Resistance at 25 °C (77 °F) : 1.6 – 1.8 kΩ at 40 °C (104 °F) : 0.5 – 0.7 kΩ HINT: As the temperature increases, the resistance decreases. 1 I05262 NG Replace ambient temperature sensor. OK Check multiplex communication system (See page DI–750). 2001 PRIUS (RM778U) DI–887 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7S7–01 DTC 13 Evaporator Temperature Sensor Circuit CIRCUIT DESCRIPTION This sensor detects the temperature inside the cooling unit and sends the appropriate signals to the A/C amplifier. DTC No. 13 Detection Item Trouble Area Open or short in evaporator temperature sensor circuit.
Evaporator temperature sensor.
Harness or connector between evaporator temperature sensor and A/C amplifier amplifier.
A/C amplifier. WIRING DIAGRAM A/C Amplifier W 2 A9 SGTE W 1 A9 TE 1 A13 A/C Thermistor 2 I18376 2001 PRIUS (RM778U) DI–888 DIAGNOSTICS 1 – AIR CONDITIONING SYSTEM Check voltage between terminals TE and SGTE of A/C amplifier connector. ON TE (+) SGTE (–) I18161 PREPARATION: (a) Remove center cluster module control with connectors still connected. (b) Turn ignition switch ON. CHECK: Measure voltage between terminals TE and SGTE of A/C amplifier connector at each temperature. OK: Voltage at 0 °C (32 °F) : 2.0 – 2.4 V at 15 °C (59 °F) : 1.4 – 1.8 V HINT: As the temperature increases, the voltage decreases. NG Go to step 2. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–874). However, if DTC 13 is displayed, check and replace A/C amplifier. 2 Check evaporator temperature sensor. Thermometer Ice Thermistor More than 10 cm (3.94 in.) Ohmmeter AC0175 PREPARATION: Remove evaporator temperature sensor (See page AC–27). CHECK: Check resistance between terminals 1 and 2 of evaporator temperature sensor connector at each temperature. OK: Resistance at 0 °C (32 °F) : 4.6. – 5.1 kΩ at 15 °C (59 °F) : 2.1 – 2.6 kΩ HINT: As the temperature increases, the voltage decreases. NG OK 2001 PRIUS (RM778U) Replace evaporator temperature sensor. DI–889 DIAGNOSTICS 3 – AIR CONDITIONING SYSTEM Check harness and connector between A/C amplifier and evaporator temperature sensor (See page IN–41). NG OK Check and replace A/C amplifier. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–890 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7S8–01 DTC 14 Engine Coolant Temperature Sensor Circuit CIRCUIT DESCRIPTION This sensor detects the engine coolant temperature and sends the appropriate signals to the A/C amplifier. These signals are used for warm up control when the engine is cold. DTC No. 14 Detection Item Trouble Area
Water temperature sensor
Harness or connector between engine coolant temp. sensor and d ECM
Harness or connector between ECM and A/C amplifier
A/C amplifier O Open or short h t in i water t temperature t t sensor circuit. i it WIRING DIAGRAM ECM W 14 E9 THW 2 E2 Engine Coolant Temp. Sensor 1 B–R 18 E9 E2 I18376 2001 PRIUS (RM778U) DI–891 DIAGNOSTICS – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 Check engine coolant temp. sensor using hand–held tester. PREPARATION: Connect the hand–held tester to the DLC3. CHECK: Check the engine coolant temp. sensor using DATA LIST. OK Check or replace A/C amplifier. NG 2 Check engine coolant temp. sensor. PREPARATION: Remove engine coolant temp. sensor. CHECK: Measure resistance between terminals. OK: Resistance is within acceptable zone on chart. S05502 NG OK 2001 PRIUS (RM778U) Water temperature Resistance 20°C (68°F) 2 – 3 kΩ 80°C (176°F) 0.2 – 0.4 kΩ Replace engine coolant temp. sensor. DI–892 DIAGNOSTICS 3 – AIR CONDITIONING SYSTEM Check for open and short in harness and connector between ECM and engine coolant temp. sensor (See page IN–41). NG Repair or replace harness or connector. OK Check multiplex communication system (See page DI–750). 2001 PRIUS (RM778U) DI–893 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7S9–01 DTC 21 Solar Sensor Circuit CIRCUIT DESCRIPTION A photo diode in the solar sensor detects solar radiation and sends signals to the A/C amplifier. Resistance of photodiode High Low Weak Strong Strength of solar radiation DTC No. 21 Detection Item Trouble Area Open or short in solar sensor circuit circuit. (Please ( note that display y of DTC 21 is not abnormal when the sensor is not receiving solar radiation.)
Solar sensor
Harness or connector between solar sensor and A/C amplifier er.
A/C amplifier. WIRING DIAGRAM A/C Amplifier 6 W A12 A/C Solar Sensor A9 S5TS 1 2 W 5 A9 TS I18378 2001 PRIUS (RM778U) DI–894 DIAGNOSTICS – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminals S5TS and TS of A/C amplifier connector. ON TS S5TS (+) (–) I18163 PREPARATION: (a) Remove center cluster module control with connectors still connected. (b) Turn ignition switch ON. CHECK: Measure voltage between terminals S5TS and TS of A/C amplifier connector when the solar sensor is subjected to an electric light, and when the sensor is covered by a cloth. OK: Condition Voltage Sensor subjected to electric light Below 4.0 V Sensor covered by a cloth 4.0 – 4.5 V HINT: As the inspection light is gradually moved away from the sensor, the voltage increases. NG Go to step 2. NG Proceed to next circuit inspection shown on problem symptoms table (See page DI–874). However, if DTC 21 is displayed, check and replace A/C amplifier. 2001 PRIUS (RM778U) DI–895 DIAGNOSTICS 2 – AIR CONDITIONING SYSTEM Check solar sensor. I00325 PREPARATION: Remove solar sensor (See page AC–59). CHECK: (a) Cover the sensor by a cloth. (b) Measure resistance between terminals 1 and 2 of solar sensor connector. HINT: Connect positive (+) lead of ohmmeter to terminal 2 and negative (–) lead to terminal 1 of the solar sensor. OK: Resistance : ∞ Ω (No continuity) PREPARATION: Remove the cloth from the solar sensor and subject the sensor to electric light. CHECK: Measure resistance. OK: Resistance : Below 10 kΩ (Continuity) HINT: As the electric light is moved gradually away from the sensor, the resistance increases. NG Replace solar sensor. OK 3 Check harness and connector between A/C amplifier and solar sensor (See page IN–41). NG OK Check and replace A/C amplifier. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–896 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7SA–01 DTC 22 Compressor Lock Sensor Circuit CIRCUIT DESCRIPTION This sensor sends 1 pulse par engine revolution to the A/C amplifier. If the number ratio of the compressor speed divided by the engine speed is smaller than a predetermined value, the A/C amplifier turns the compressor off. And, the indicator flashes at about 1 sec. intervals. DTC No. 22 Detection Item Trouble Area All conditions diti below b l are detected d t t d for f 3 secs. or more. ( ) Engine (a) E i speed d : 450 rpm or more. (b) Ratio between engine and compressor speed deviates 20 % or more in comparison to normal operation operation.
Com Compressor ressor
Com Compressor ressor drive belt
Com Compressor ressor lock sensor
Harness or connector between com compressor ressor and A/C am amplifier lifier
A/C amplifier WIRING DIAGRAM A/C Amplifier 4 IK1 W–L 4 IE1 W–L 5 IK1 BR–W 5 IE1 BR–W 9 A8 LOCK W–L 4 Compressor Lock Sensor 2 BR–W 18 A8 SG LOCK I18379 2001 PRIUS (RM778U) DI–897 DIAGNOSTICS – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 Check compressor. PREPARATION: (a) Check compressor drive belt tension (See page AC–15). (b) Check if the compressor does not lock during operation with engine started and blower switch and A/C switch ON. NG Adjust drive belt tension or repair compressor. OK 2 Check compressor lock sensor. 2 4 PREPARATION: Disconnect compressor lock sensor connector. CHECK: Measure resistance between terminals 2 and 4 of compressor lock sensor connector. OK: Resistance : at 20 °C (68 °F) : 65 – 125 Ω I18005 Reference : Inspection using oscilloscope During cranking or idling, measure voltage between terminals LOCK signal waveform LOCK and SGLOCK of A/C amplifier. LCK1 HINT: The correct waveform appears as shown in the illustration on 0.2 V/Din. the left. 0V 20 msec/Division (Idling) N02774 NG OK 2001 PRIUS (RM778U) Replace compressor. DI–898 DIAGNOSTICS 3 – AIR CONDITIONING SYSTEM Check harness and connector between A/C amplifier and compressor lock sensor (See page IN–41). NG Repair or replace harness or connector. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–874). However, if DTC 22 is displayed, check and replace A/C amplifier. 2001 PRIUS (RM778U) DI–899 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7SB–01 DTC 23 Pressure Switch Circuit CIRCUIT DESCRIPTION This pressure switch sends the appropriate signals to the A/C amplifier when the A/C refrigerant pressure drops too low or rises too high. When the A/C amplifier receives these signals, if outputs signals via the A/C amplifier to switch off the compressor relay and turns the magnetic clutch off. DTC No. Detection Item Trouble Area
Pressure switch
Harness or connector between pressure switch and A/C amplifier lifi
Refrigerant pipe line
A/C amplifier
Open in pressure sensor circuit. circuit
Abnormal refrigerant pressure. ressure. below 196 kPa (2.0 kgf/cm2. 28 psi) over 3,140 kPa (32.0 kgf/cm2. 455 psi) 23 WIRING DIAGRAM A/C amplifier 15 W–B IE1 L–Y 11 A8 PSW 1 A3 A/C Dual Pressure Switch W–B 4 A J1 J/C ED I08340 2001 PRIUS (RM778U) DI–900 DIAGNOSTICS – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminals PSW of A/C amplifier and body ground. ON PSW (+) (–) I18170 PREPARATION: (a) Install the manifold gauge set (See page AC–18). (b) Remove the center cluster module control with connectors still connected. (c) Turn ignition switch ON. CHECK: Check voltage between terminals PSW of A/C amplifier connector and body ground when refrigerant pressure is changed. OK: The voltage changes refrigerant pressure, as shown in the chart below. Low Pressure Cut Side 225 kPa 196 kPa OFF (12V) OK NG 2001 PRIUS (RM778U) Referaence : High Pressure Cut SIde ON (0 V) ON (0 V) 2,550 kPa 3,140 kPa OFF (12V) Proceed to next circuit inspection shown on problem symptoms table (See page DI–874). DI–901 DIAGNOSTICS 2 – AIR CONDITIONING SYSTEM Check pressure switch. 1 3 2 4 PREPARATION: Disconnect pressure switch connector. CHECK: Check continuity between terminals 1 and 4 of pressure switch when refrigerant is changed. OK: The continuity changes with refrigerant pressure as shown in the chart below. Low Pressure Cut Side I18025 Referaence : High Pressure Cut SIde ON (Continuity) ON (Continuity) 225 kPa 2,550 kPa 196 kPa OFF (No continuity) NG 3,140 kPa OFF (No continuity) Replace pressure switch. OK 3 Check harness and connector between A/C amplifier and pressure switch, pressure switch and body ground (See page IN–41). NG OK Check and replace A/C amplifier. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–902 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7SC–01 DTC 31, 41 Air Mix Damper Position Sensor Circuit CIRCUIT DESCRIPTION TPI terminal voltage (V) This sensor detects the position of the air mix damper and sends the appropriate signals to the A/C amplifier. The position sensor is built into the air mix control servomotor. 4 1 0 Damper opening angle 100% DTC No. Detection Item Trouble Area 31 Short to ground or power source circuit in air mix damper position sensor circuit. 41 Air mix dam damper er position osition sensor value does not change even if A/C amplifier operates air mix control servomotor.
Air mix damper position sensor.
Harness of connector between air mix control servomotor and A/C amplifier.
A/C amplifier. WIRING DIAGRAM A16 Air Mix Control Servomotor A/C Amplifier W–R 1 BR–W 6 II1 W 17 A9 S5TP 8 II1 W 15 A9 SGTP 7 II1 W 16 A9 TP 2 3 B Y–R V I18402 2001 PRIUS (RM778U) DI–903 DIAGNOSTICS – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminals TP and SGTP of A/C amplifier connector. ON SGTP TP (+) (–) I18165 PREPARATION: (a) Remove center cluster module control with connectors still connected. (b) Turn ignition switch ON. CHECK: Change the set temperature to activate the air mix damper, and measure the voltage between terminals TP and SGTP of A/C amplifier connector each time when the set temperature is changed. OK: Set Temperature Voltage Max. COOL 3.5 – 4.5 V Max. WARM 0.5 – 1.8 V HINT: As the set temperature increases, the voltage decreases gradually without interruption. NG Go to step 2. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–874). However, if DTC 31 or 41 is displayed, check and replace A/C amplifier. 2001 PRIUS (RM778U) DI–904 DIAGNOSTICS 2 – AIR CONDITIONING SYSTEM Check air mix damper position sensor. WARM 1 2 COOL 3 I19076 PREPARATION: Remove air mix control servomotor (See page AC–56). CHECK: Measure resistance between terminals 1 and 2 of air mix control servomotor connector. OK: Resistance : 4.2 – 7.8 kΩ CHECK: While operating air mix control servomotor as shown in the procedure on page DI–906, measure resistance between terminals 2 and 3 of air mix control servomotor connector. OK: Position Resistance Max. COOL 3.6 – 6.7 kΩ Max. WARM 0.6 – 1.1 kΩ HINT: As the air mix control servomotor moves from cool side to hot side, the resistance decreases gradually without interruption. NG Replace air mix control servomotor. OK 3 Check harness and connector between A/C amplifier and air mix control servomotor (See page IN–41). NG OK Check and replace A/C amplifier. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–905 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7SD–01 DTC 32, 42 Air Inlet Damper Position Sensor Circuit CIRCUIT DESCRIPTION This sensor detects the position of the air inlet damper and sends the appropriate signals to the A/C amplifier. The position sensor is built into the air inlet control servomotor. TPI terminal voltage (V) 4 4.1 V 0.9 V 1 0 Damper opening angle100% DTC No. 32 42 Detection Item Trouble Area Short to ground or power ower source circuit in air inlet damper dam er posiosi tion sensor circuit. Air inlet damper position sensor value does not change even if A/C amplifier operates air inlet control servomotor.
Air inlet damper position sensor
Harness or connector between air inlet control servomotor and A/C amplifier
A/C amplifier WIRING DIAGRAM A14 Air Inlet Control Servomotor A/C Control Assembly 3 W 19 A9 TPI 1 W 18 A9 SGTPI 2 W 18 A9 S5TPI I14169 2001 PRIUS (RM778U) DI–906 DIAGNOSTICS – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminals TPI and SGTPI of A/C amplifier connector. ON SGTPI TPI (+) (–) I18164 PREPARATION: (a) Remove center cluster module control with connectors still connected. (b) Turn ignition switch ON. CHECK: Press REC/FRS switch to change air inlet between fresh and recirculation air and measure voltage between terminals TPI and SGTPI of A/C amplifier when the air inlet servomotor operates. OK: REC/FRS Switch Voltage REC 3.5 – 4.5 V FRS 0.5 – 1.8 V HINT: As the air inlet control servomotor is moved from REC side to FRS side, the voltage decreases gradually without interruption. NG Go to step 2. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–874). However, if DTC 32 or 42 is displayed, check and replace A/C amplifier. 2001 PRIUS (RM778U) DI–907 DIAGNOSTICS 2 – AIR CONDITIONING SYSTEM Check air inlet damper position sensor. REC 1 FRS 2 3 I19077 PREPARATION: Remove air inlet control servomotor (See page AC–33). CHECK: Measure resistance between terminals 1 and 2 of air inlet control servomotor connector. OK: Resistance : 4.2 – 7.8 kΩ CHECK: While operating air inlet control servomotor as in the procedure on page DI–909, measure resistance between terminals 2 and 3 of air inlet control servomotor connector. OK: Resistance : Damper Position Resistance REC side 3.4 – 6.2 kΩ FRS side 0.8 – 1.6 kΩ HINT: As the air inlet control servomotor is moved from REC side to FRS side, the resistance decreases gradually without interruption. NG Replace air inlet control servomotor. OK 3 Check harness and connector between A/C amplifier and air inlet control servomotor (See page IN–41). NG OK Check and replace A/C amplifier. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–908 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7SE–01 DTC 33, 43 Air Outlet Damper Position Sensor Circuit CIRCUIT DESCRIPTION This sensor detects the position of the air outlet damper and sends the appropriate signals to the A/C amplifier. The position sensor is built into the air outlet damper control servomotor assembly. TPM terminal voltage (V) 4.3 0.7 0 100 % Damper opening angle DTC No. Detection Item Trouble Area 33 Short to ground or power source circuit in air outlet damper position sensor circuit. 43 Air outlet damper position sensor value does not change even if A/C amplifier operates air outlet damper control servomotor.
Air outlet damper position sensor.
Harness or connector between air outlet damper dam er control servomotor assembly and A/C amplifier.
A/C amplifier. WIRING DIAGRAM A16 Air Outlet Control Servomotor 1 W 2 BR–W A/C Amplifier 5 II1 W 7 A9 3 II1 W 9 A9 SGTPM 4 II1 W 8 A9 S5TPM 3 GR–L TPM I18402 2001 PRIUS (RM778U) DI–909 DIAGNOSTICS 1 – AIR CONDITIONING SYSTEM Check voltage between terminals TPM and SGTPM of A/C amplifier connector. ON PREPARATION: (a) Remove center cluster module control with connectors still connected. (b) Turn ignition switch ON. CHECK: Measure the voltage between terminals TPM and SGTPM of A/C amplifier. OK: SGTPM TPM (+) (–) I18166 Air inlet selector Voltage FACE 3.5 – 4.5 V DEF 0.5 – 1.5 V HINT: As the air outlet damper control servomotor is moved from FACE side to DEF side, the voltage decreases gradually without interruption. NG Go to step 2. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–874). However, if DTC 34 or 44 is displayed, check and replace A/C amplifier. 2001 PRIUS (RM778U) DI–910 DIAGNOSTICS 2 – AIR CONDITIONING SYSTEM Check air outlet damper position sensor. DEF FACE 1 2 3 I19078 PREPARATION: Remove air outlet servomotor (See page AC–57). CHECK: Measure resistance between terminals 1 and 2 of air outlet servomotor assembly connector. OK: Resistance : 4.2 – 7.8 kΩ CHECK: While operating air outlet damper control servomotor as in the procedure on page DI–912, measure resistance between terminals 2 and 3 of air outlet damper control servomotor. OK: Resistance: Damper Position Resistance DEF 3.6 – 6.7 kΩ FACE 0.6 – 1.1 kΩ HINT: As the air outlet servomotor moves from DEF side to FACE side, the resistance decreases gradually without interruption. NG Replace air outlet control servomotor assembly. OK 3 Check harness and connector between A/C amplifier and air outlet control servomotor assembly (See page IN–41). NG OK Check and replace A/C amplifier. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–911 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7SF–01 DTC 41 Air Mix Control Servomotor Circuit CIRCUIT DESCRIPTION This air mix control servomotor is controlled by the A/C amplifier and moves the air mix damper to the desired position. DTC No. 41 Detection Item Trouble Area Air mix dam damper er position osition sensor value does not change even if A/C amplifier operates air mix control servomotor.
Air mix control servomotor.
Air mix damper position sensor.
Harness H or connector t b between t A/C amplifier lifi and d air i mix i control servomotor, air mix damper position sensor.
A/C amplifier. WIRING DIAGRAM A15 Air Mix Control Servomotor L 5 BR–R Instrument Panel J/B HTR IG1 Relay 3 5 2 1 AM1 3 2D 1 2H 6 2D 8 2K 14 9 II1 4 A9 W AMC 13 10 II1 W J20 J/C C C A/C Amplifier R R A9 AMH 1 A7 IG B–Y 4 W IG1 I15 Ignition SW AM1 3 2B W–G 8 2D A J24 2 J/C 7 A7 A J25 GND W–B F18 FL Block No. 2 MAIN 1 Battery FL Block No. 1 1 1 F11 F13 DC/DC W–B A J11 J/C ID I18391 2001 PRIUS (RM778U) DI–912 DIAGNOSTICS – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 Actuator check. PREPARATION: (a) Warm up the engine. (b) Set to the actuator check mode (See page DI–866). CHECK: Operate the temperatur control switch and check the operation of the air mix damper and the condition of the blower. OK: Condition –10 % (Fully closed) Cool air comes out 21.0 ↔ 23.5 (67 ↔ 72) → Max. COOL ↔ 20.5 (66) Air Mix Damper 24.0 ↔ 26.0 (73 ↔ 77) 50 % 29.5 (84) ↔ Max. WARM → 26.5 ↔ 29.0 (78 ↔ 83) 100 % (Fully opened) OK NG 2001 PRIUS (RM778U) → Temp. Setting °C (°F) Warm air comes out Proceed to next circuit inspection shown on problem symptoms table (See page DI–874). DI–913 DIAGNOSTICS 2 – AIR CONDITIONING SYSTEM Check air mix control servomotor. 4 5 To COOL (+) PREPARATION: Remove air mix control servomotor (See page AC–56). CHECK: Connect positive (+) lead to terminal 4 and the negative (–) lead to terminal 5. OK: The lever turns smoothly to COOL side. (–) I19079 CHECK: Connect negative (–) lead to terminal 4 and positive (+) lead to terminal 5. OK: The lever turns smoothly to WARM side. 4 To WARM 5 (–) (+) I19080 NG Replace air mix control servomotor. OK 3 Check harness and connector between A/C amplifier and air mix control servomotor (See page IN–41). NG OK Check and replace A/C amplifier. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–914 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7SG–01 DTC 42 Air Inlet Control Servomotor Circuit CIRCUIT DESCRIPTION The air inlet control servomotor is controlled by the A/C amplifier and moves the air inlet damper to the desired position. DTC No. Detection Item Trouble Area 42 Air inlet damper position sensor value does not change even if A/C amplifier operates air inlet control servomotor. servomotor
Air inlet damper position sensor
Harness or connector between air inlet control servomotor and A/C amplifier
A/C amplifier WIRING DIAGRAM 4 W 5 W 22 A9 A15 Air Inlet Control Servomotor Instrument Panel J/B HTR IG1 Relay 3 5 2 1 AM1 3 2D 1 2H 6 2D 8 2K A/C Amplifier AIF 21 A9 AIR 1 A7 IG J20 J/C C C R R B–Y 4 W IG1 3 W–G 2B 8 2D A J22 I15 Ignition SW AM1 2 J/C 7 A7 A J23 GND W–B F18 FL Block No. 2 MAIN 1 B–G Battery FL Block No. 1 1 1 DC/DC F11 F13 W–B A J11 J/C ID I18403 2001 PRIUS (RM778U) DI–915 DIAGNOSTICS – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 Actuator check. FRS REC I18150 PREPARATION: (a) Remove glove compartment door to see and check the air inlet damper operation. (b) Set to the actuator check mode (See page DI–866). (c) Operate the temperature control switch and change it to step operation. CHECK: Operate the temperature control switch and check the operation air inlet damper. OK: OK NG 2001 PRIUS (RM778U) Temp. setting °C (°F) Air Inlet Damper Max. COOL ↔ 20.5 (66) REC 21.0 ↔ 26.0 (67 ↔ 77) REC/FRS 26.5 (78) ↔ Max. WARM FRS Proceed to next circuit inspection shown on problem symptoms table (See page DI–874). DI–916 DIAGNOSTICS 2 – AIR CONDITIONING SYSTEM Check air inlet control servomotor. To FRS 5 PREPARATION: Remove air inlet control servomotor (See page AC–33). CHECK: Connect positive (+) lead from the battery to terminal 4 and negative (–) lead to terminal 5. OK: The lever moves smoothly to FRS position. 4 I19081 To REC CHECK: Connect negative (+) lead from the battery to terminal 5 and positive (–) lead to terminal 4. OK: The lever moves smoothly to REC position. 4 5 (+) (–) I19082 NG Replace air inlet control servomotor assembly. OK 3 Check harness and connector between A/C amplifier and air inlet control servomotor (See page IN–41). NG OK Check and replace A/C amplifier. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–917 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7SH–01 DTC 43 Air Outlet Damper Control Servomotor Circuit CIRCUIT DESCRIPTION This circuit turns the servomotor and changes each mode damper position by the signals from the A/C amplifier. When the AUTO switch is on, the A/C amplifier changes the mode automatically between (FACE), (BI– LEVEL) and (FOOT) according to the temperature setting. DTC No. 43 Detection Item Trouble Area Air outlet dam damper er position osition sensor value does not change even if A/C amplifier operated air outlet damper control servomotor.
Air outlet damper dam er control servomotor.
Air outlet damper position sensor.
Harness H or connector t between b t A/C amplifier lifi air i outlet tl t damper d control servomotor, air outlet damper position sensor.
A/C amplifier. 2001 PRIUS (RM778U) DI–918 DIAGNOSTICS – AIR CONDITIONING SYSTEM WIRING DIAGRAM 4 A16 Air Outlet Servomotor L 5 BR–R Instrument Panel J/B HTR IG1 Relay 3 5 2 1 AM1 3 2D 1 2H 6 2D 8 2K 10 2 II1 A9 W AOF 10 1 II1 W J20 J/C C C A/C Amplifier R R A9 AOD 1 A7 IG B–Y 4 W IG1 I15 Ignition SW AM1 3 2B W–G 8 2D A J22 2 J/C 7 A7 A J23 GND W–B F18 FL Block No. 2 MAIN 1 Battery FL Block No. 1 1 1 DC/DC F11 F13 W–B A J11 J/C ID I18391 2001 PRIUS (RM778U) DI–919 DIAGNOSTICS – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 Actuator check. Temp. setting °C (°F) Air Flow Max. COOL ↔ 20.5 (66) FACE 21.0 ↔ 23.5 (67 ↔ 72) B/L 24.0 ↔ 26.0 (73 ↔ 77) FOOT 26.5 ↔ 29.0 (78 ↔ 83) DEF 29.5 (84) ↔ Max. WARM FOOT/DEF PREPARATION: (a) Set to the actuator check mode (See page DI–866). (b) Press the DEF switch and change to step operation. CHECK: Press the DEF switch in order and check the condition of air flow mode. OK: The mode changes with the change in the temperature setting as shown in the table. OK NG 2001 PRIUS (RM778U) Proceed to next circuit inspection shown on problem symptoms table (See page DI–874). DI–920 DIAGNOSTICS 2 – AIR CONDITIONING SYSTEM Check air outlet control servomotor. To FACE PREPARATION: Remove air outlet control servomotor (See page AC–57). CHECK: Connect positive (+) lead to terminal 4 and negative (–) lead to terminal 5. OK: The lever moves smoothly to FACE position. 4 5 I19083 To FACE 5 (+) CHECK: Connect positive (+) lead to terminal 5 and negative (–) lead to terminal 4. OK: The lever moves smoothly to DEF position. 4 (–) I19084 NG Replace air outlet servomotor. OK 3 Check for open and short in harness and connector between A/C amplifier and air outlet servomotor (See page IN–41). NG OK Check and replace A/C amplifier. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–921 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7SI–01 IG Power Source Circuit CIRCUIT DESCRIPTION This is the power source for the A/C amplifier (contains the ECU) and servomotors, etc. WIRING DIAGRAM A/C Amplifier Instrument Panel J/B HTR 3 2D 6 2D 1 IG 7 A7 GND B–Y 4 AM1 3 2B 8 2D F18 FL Block No. 2 Battery 1 A7 R 8 2K MAIN C 1 2H 5 2 C R IG1 Relay 3 J20 J/C 4 B–G FL Block No. 1 1 DC/DC F13 F11 1 IG1 I15 Ignition SW AM1 2 W A W–B J24 J/C A J25 W–B A J11 J/C ID I18389 2001 PRIUS (RM778U) DI–922 DIAGNOSTICS – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminals IG and GND of A/C amplifier connector. ON IG (–) (+) I18168 PREPARATION: (a) Remove center cluster module control with connectors still connected. (b) Turn ignition switch ON. CHECK: Measure voltage between terminals IG and GND of A/C amplifier. OK: Voltage : 10 – 14 V OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–874). NG 2 Check continuity between terminal GND of A/C amplifier and body ground. CHECK: Measure resistance between terminal GND of A/C amplifier and body ground. OK: Resistance : Below 1 Ω GND (+) (–) I18167 NG OK 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–923 DIAGNOSTICS 3 – AIR CONDITIONING SYSTEM Check HTR fuse. PREPARATION: Remove HTR fuse from instrument panel J/B. CHECK: Check continuity of HTR fuse. OK: Continuity exists. Instrument Panel J/B HTR Fuse I18410 NG Check for shot in all the harness and components connected to the HTR fuse. OK Check and repair harness and connector between A/C amplifier and battery. 2001 PRIUS (RM778U) DI–924 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7SJ–01 Back Up Power Source Circuit CIRCUIT DESCRIPTION This is the back–up power source for the A/C amplifier. Power is supplied even when the ignition switch is off. WIRING DIAGRAM Instrument Panel J/B 1 2H W ECU–B 5 2C J25 J/C F R–G F R–G 8 A7 A/C Amplifier +B 1 F11 DC/DC FL Block No. 1 1 F13 B–G MAIN F18 FL Block No. 2 Battery I18385 2001 PRIUS (RM778U) DI–925 DIAGNOSTICS – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminal +B of A/C amplifier connector and body ground. PREPARATION: Remove A/C amplifier with connectors still connected. CHECK: Measure voltage between terminal +B of A/C amplifier connector and body ground. OK: Voltage : 10 – 14 V +B (–) (+) I18172 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–874). NG 2 Check ECU–B fuse. PREPARATION: Remove ECU–B fuse from instrument panel J/B. CHECK: Check continuity of ECU–B fuse. OK: Continuity exists. Instrument Panel J/B ECU–B Fuse I18410 NG Check for short in all the harness and components connected to the ECU–B fuse (See page IN–41). OK Check and repair harness and connector between A/C amplifier and battery. 2001 PRIUS (RM778U) DI–926 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7SK–01 Heater Main Relay Circuit CIRCUIT DESCRIPTION The heater main relay is switched on by signals from the A/C amplifier. It supplies power to the blower motor. WIRING DIAGRAM C11 Combination Meter Body ECU 10 MPX+ B8 GR–B 2 GR 13 E10 13 6 L–O 1J 2F HRLY 8 1K To Blower Motor 14 E10 MPX2 Instrument Panel J/B 3 GR 11 A7 MPX+ GR–B 4 A7 MP2+ C1 Gateway ECU ECM 11 MPX– B8 MPX+ MPX– A/C Amplifier MPX1 11 GR–L MPD2 4 MPD1 J6 J/C Engine Room J/B HTR Relay 3 4 1F 5 R R B B HTR 13 IE1 2 3 1B W R A J23 3 1K J/C Instrument Panel J/B 1 F11 FL Block DC/DC No. 1 1 2H W 1 F13 B–G C J22 3 2B AM1 W–G 2 I15 Ignition SW AM1 IG1 Relay R W–B 1 MAIN F18 FL Block No. 2 8 2K 3 5 2 1 6 2D HTR Battery IG1 4 B–Y 3 2D J11 J/C A W–B A J1 J/C A J7 J/C A ID IE I18388 2001 PRIUS (RM778U) DI–927 DIAGNOSTICS – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 3 Check heater main relay. 4 PREPARATION: Remove heater main relay from engine room J/B. CHECK: Check continuity between each pair of terminals of heater main relay shown below. OK: 5 3 5 4 1 2 2 1 BE1850 BE1844 I00312 Tester connection Specified condition 1–4 No continuity 2–4 Continuity 3–5 62.5 – 90.9 Ω PREPARATION: Apply battery positive voltage between terminals 3 and 5. CHECK: Check continuity between each pair of terminal shown below. OK: NG Tester connection Specified condition 1–2 Continuity 2–4 No continuity Replace hater main relay. OK 2 Check HTR fuse PREPARATION: Remove HTR fuse from engine room J/B. CHECK: Check continuity of HTR fuse. OK: Continuity exists. Engine Room J/B HTR Fuse NG I18394 OK 2001 PRIUS (RM778U) Check for short in all the harness and components connected to the HTR fuse (See page IN–41). DI–928 DIAGNOSTICS 3 – AIR CONDITIONING SYSTEM Check harness and connector between heater main relay and body ground, heater main relay and body ECU (See page IN–41). NG Check and replace harness and connector. OK Check multiplex communication system (See page DI–750). 2001 PRIUS (RM778U) DI–929 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7SL–01 Blower Motor Circuit CIRCUIT DESCRIPTION Blower Level The blower motor is operated by signals from the A/C amplifier. Blower motor speed signals are transmitted by changes in the Duty Ratio. Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity in one cycle, and B is the period of non–continuity, then. HI M2 M1 LO 0 30 43 67 100 Si duty (%) Duty Ratio = A A+B x 100 (%) A ON OFF B 1 cycle WIRING DIAGRAM J6 J/C C A/C Amplifier C V V 21 IE1 V 3 A7 BLW B7 Blower Motor Liner Controller From HTR Relay A J2 J/C SI GND A J3 W–B +B A J2 A J1 J/C VM B6 Blower Motor 2001 PRIUS (RM778U) IE I18383 DI–930 DIAGNOSTICS – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 Check blower motor. PREPARATION: Remove blower motor (See page AC–33). CHECK: Connect positive (+) lead connected to terminal 2 of blower motor connector, negative (–) lead to terminal 1. OK: Blower motor operates smoothly. N16333 NG Replace blower motor. OK 2 Check harness and connector between battery and blower motor, blower motor and body ground (See page IN–41). NG Repair or replace harness or connector. OK 3 Check harness and connector between blower motor linear controller and A/C amplifier (See page IN–41). NG OK 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–931 DIAGNOSTICS 4 – AIR CONDITIONING SYSTEM Check A/C amplifier (See page IN–41). NG OK Replace blower motor linear controller. 2001 PRIUS (RM778U) Replace A/C amplifier. DI–932 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7SM–01 Compressor Circuit CIRCUIT DESCRIPTION A/C amplifier switches the A/C magnetic clutch relay ON, thus turning the A/C compressor magnetic clutch ON. WIRING DIAGRAM ECM A/C Amplifier 5 A8 ACT 22 ACT E10 Engine Room J/B CLR MG Relay 1 2 5 3 3 1F 5 1A 4 1F Instrument Panel J/B HTR IG1 Relay 3 2 3 2D 8 IE1 LG–R 6 2D 1 J6 J/C 13 IE1 A A R R R R J/C C J20 A J21 B–Y W 4 IG1 I15 Ignition SW 2K AM1 Battery MGC B–L 8 B–G 10 A8 1 2H 5 F18 FL Block No. 2 MAIN 1 LG–R AM1 3 2B 2 W–G W–B FL Block No. 1 1 1 DC/DC F13 F11 1 A2 A/C Magnetic Clutch A J11 J/C ID I18387 2001 PRIUS (RM778U) DI–933 DIAGNOSTICS – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminal MGC of A/C amplifier and body ground. CHECK: (a) Start engine. (b) Push AUTO SW. (c) Measure voltage between terminal MGC of A/C amplifier connector and body ground when A/C switch is On and OFF. OK: MGC ON (+) (–) I18169 OK A/C switch Voltage ON Below 0.7 V OFF 10 – 14 V Go to step 5. NG 2 Check magnetic clutch relay. 2 1 3 5 3 1 2 PREPARATION: Remove magnetic clutch relay from engine room J/B. CHECK: Check continuity between each pair of terminals shown below of magnetic clutch relay. OK: 5 Z18060 Tester connection Specified condition 1–2 62.5 – 90.9 Ω 3–5 No continuity PREPARATION: Apply battery positive (+) voltage between terminals 1 and 2. CHECK: Check continuity between terminals 3 and 5. OK: Continuity exists. NG OK 2001 PRIUS (RM778U) Replace magnetic clutch relay. DI–934 DIAGNOSTICS 3 – AIR CONDITIONING SYSTEM Check A/C magnetic clutch. 1 PREPARATION: Disconnect magnetic clutch connector. CHECK: Connect positive (+) lead connected to battery to magnetic clutch connector terminal 3 and negative (–) lead to body ground. OK: Magnetic clutch is energized. I18006 NG Repair A/C magnetic clutch. OK 4 Check harness and connector between magnetic clutch relay and A/C amplifier, A/C compressor and body ground (See page IN–41). NG Repair or replace harness or connector. OK Proceed to next circuit inspection shown on problem symptons table (See page DI–874). 5 Check voltage between terminal ACT of A/C amplifier connector side and body ground. PREPARATION: (a) Disconnect A/C amplifier connector. (b) Turn ignition switch ON. CHECK: Check voltage between terminal ACT of A/C amplifier harness side connector. OK: Voltage : 10 – 14 V ACT I18156 NG OK 2001 PRIUS (RM778U) Check and replace engine ECU. DI–935 DIAGNOSTICS 6 – AIR CONDITIONING SYSTEM Check voltage between terminal ACT of A/C amplifier connector and body ground. ON ACT (+) (–) I18157 PREPARATION: (a) Remove center cluster module control with connector still connected. (b) Start the engine and push AUTO switch. CHECK: Check the voltage between terminal ACT of A/C amplifier connector and body ground when magnetic clutch is ON and OFF by A/C switch. OK: NG Magnetic clutch Voltage ON 10 – 14 V OFF Below 1.0 V Check and replace A/C amplifier. OK 7 Check harness and connector between magnetic clutch relay and A/C amplifier (See page IN–41). NG OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–874). 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–936 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7SN–01 Water Pump Circuit CIRCUIT DESCRIPTION This is hte power source for the water pump motor. WIRING DIAGRAM A/C Amplifier Engine Room R/B No. 3 R J6 J/C 3 A/C W/P Relay 1 2 3 20 IE1 L–R L–R 3 A9 WP L A A 3 R 3 R 13 R IE1 Instrument Panel J/B HTR A J21 5 J/C 3 C J20 1 W2 Water Pump Motor R 3 2D 2 IG1 Relay 3 2B 3 5 2 1 6 2D 1 2H 8 2K AM1 W–G 2 4 AM1 IG1 I15 Ignition SW 1 MAIN Battery B–G F18 FL Block No. 2 B–Y W–B A W J7 J/C A A A J11 J/C 1 1 DC/DC F13 F11 ID J1 J/C IE FL Block No. 1 I18381 2001 PRIUS (RM778U) DI–937 DIAGNOSTICS – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminal WP of A/C amplifier and body ground. ON WP (+) (–) I18171 PREPARATION: (a) Remove the center cluster module control with connectors still connected. (b) Start engine. (c) Operate blower motor. CHECK: Measure voltage between terminal WP of A/C amplifier and body ground when each condition as shown in the chart. OK: OK condition Voltage Engine running 10 – 14 V Engine stop Below 1.0 V Proceed to next circuit inspection shown on problem symptoms table (See page DI–874). NG 2 Check A/C water pump relay. 2 1 3 5 3 1 2 5 PREPARATION: Remove the A/C water pump relay from engine room R/B NO. 3. CHECK: Check continuity between each pair of terminals shown below of magnetic clutch relay. OK: Z18060 Tester connection Specified condition 1–2 62.5 – 90.9 Ω 3–5 No continuity PREPARATION: Apply battery positive (+) voltage between terminals 1 and 2. CHECK: Check continuity between terminals 3 and 5. OK: Continuity exists. NG OK 2001 PRIUS (RM778U) Replace magnetic clutch relay. DI–938 DIAGNOSTICS 3 2 (–) – AIR CONDITIONING SYSTEM Check water pump motor. 1 (+) 6 Dry Cell Batteries I18018 PREPARATION: Remove the water pump (See page AC–55). CHECK: Connect the positive (+) lead from the 6 dry cell batteries (7 – 10.5 V) to terminal 1 and negative (–) lead to terminal 2, then check that the motor operation. NOTICE:
Do not apply battery voltage.
Operate without water should be done within 10 sec. OK: Motor operation smoothly. NG Replace water pump. OK 4 Check harness and connector between water pump motor and A/C amplifier, water pump motor and body ground (See page IN–41). NG OK Check and replace A/C amplifier. 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–939 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7SO–01 Converter Circuit WIRING DIAGRAM C4 Converter A/C Amplifier 2 Y 14 IE1 Y 10 A7 IDH I18392 2001 PRIUS (RM778U) DI–940 DIAGNOSTICS – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminal IDH of A/C amplifier and body ground. ON IDH (–) (+) I18158 PREPARATION: Remove the center cluster module control with connectors still connected. CHECK: (a) Turn ignition switch ON. (b) Turn light control switch OFF. (c) Turn rear defogger switch OFF. (d) Measure voltage between terminal IDH of A/C amplifier. OK: Voltage: Below 1.0 V OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–874). NG 2 Check voltage between terminal IDH of A/C amplifier and body ground. ON IDH I18398 PREPARATION: Disconnect the connector from A/C amplifier. CHECK: (a) Turn ignition switch ON. (b) Turn light control switch OFF. (c) Turn rear defogger switch OFF. (d) Measure voltage between terminal IDH of A/C amplifier on wire harness side connector. OK: Voltage: Below 1.0 V OK NG 2001 PRIUS (RM778U) Check and replace A/C amplifier. DI–941 DIAGNOSTICS 3 – AIR CONDITIONING SYSTEM Check harness and connector between A/C amplifier and converter (See page IN–41). NG OK Check and replace converter. 2001 PRIUS (RM778U) Repair and replace harness and connector. DI–942 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7SP–01 PTC Heater Circuit (Quick Heater) CIRCUIT DESCRIPTION A/C amplifier switches the HTR3 relay ON by signal from the A/C amplifier. It supplies power to PTC heater (Quick heater). 2001 PRIUS (RM778U) DI–943 DIAGNOSTICS – AIR CONDITIONING SYSTEM WIRING DIAGRAM Engine Room R/B No.3 HTR3 Relay 3 3 1 2 3 3 5 3 R–L G R–L P P–B HTR2 Relay 3 G–W 1 3 2 5 3 HTR1 Relay R–L 3 3 1 2 3 5 A/C Amplifier 13 A8 HTR2 P L–R 16 P–B IE1 6 A8 HTR0 3 3 P–B 3 L–Y 3 HTR1 B–R 18 IE1 G–R 3 HTR2 3 1 P2 3 1 P1 P2 HTR3 PTC Heater 3 W 2 P2 3 4 P2 2 P1 Instrument Panel J/B GAUGE 8 2G IG1 Relay 3 2B 3 5 2 1 6 2D 1 2H 8 2K AM1 W–B I15 Ignition SW W–G 2 AM1 IG1 F18 FL Block No.2 MAIN Battery W–B 4 1 IA1 B–Y FL Block No.1 1 F13 W–B 1 1 F13 W–B A A A A F13 DC/DC W–B W–B 5 IA1 W J1 J/C IE J11 J/C ID I18386 2001 PRIUS (RM778U) DI–944 DIAGNOSTICS – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 Check converter circuit (See page DI–934). 2 Check voltage between terminal HTR2 of A/C amplifier and body ground. ON HTR2 (+) (–) I18174 PREPARATION: Remove the center cluster module control with connectors still connected. CHECK: (a) Start engine. (b) Set temperature control switch on ”MAX. WARM” position. (c) Set blower switch on ”HI” position. (d) Turn light control switch OFF. (e) Turn defogger switch OFF. (f) Check voltage between terminal HTR2 of A/C amplifier and body ground at each conditions, as shown in the chart. OK: Condition
Air flow selector: FOOT
Water temp. : Below 65°C (149°F) Below 0.7 V
Air flow selector: FOOT/DEF
Water temp. : Below 60°C (140°F) Below 0.7 V
Air flow selector: DEF
Water temp. : 75°C (167°F) Below 0.7 V OK NG 2001 PRIUS (RM778U) Voltage Go to step 6. DI–945 DIAGNOSTICS 3 – AIR CONDITIONING SYSTEM Check HTR3 fuses. PREPARATION: Remove the HTR3 fuse from engine room R/B No. 3. CHECK: Check continuity of HTR1 and HTR2 fuses. OK: Continuity exists. Engine Room R/B No. 3 HTR3 Fuse I18396 NG Check for short in all the harness and components connected to the HTR1 and HTR2 fuses (See attached wiring diagram). OK 4 Check HTR3 relays. 2 1 3 5 3 1 2 PREPARATION: Remove the HTR3 relays from engine room relay block No. 3. CHECK: Check continuity between each pair of terminals shown below of magnetic clutch relay. OK: 5 Z18060 Tester connection Specified condition 1–2 62.5 – 90.9 Ω 3–5 No continuity PREPARATION: Apply battery positive (+) voltage between terminals 1 and 2. CHECK: Check continuity between terminals 3 and 5. OK: Continuity exists. NG OK 2001 PRIUS (RM778U) Replace HTR3 relay. DI–946 DIAGNOSTICS 5 – AIR CONDITIONING SYSTEM Check harness and connector between A/C amplifier and HTR1 and HTR2 fuses (See page IN–41). NG Check and replace harness and connector. OK Check and replace A/C amplifier. 6 Check PTC heater. PREPARATION: Remove the heater radiator (See page AC–51). CHECK: Check continuity between terminals of PTC heater connector, as shown in the chart. OK: I18393 NG Tester connection Result 1–2 Continuity 3–4 Continuity Replace heater radiator. OK Check harness and connector between PTC heater and HTR1, HT2 relays, PTC heater and body ground (See page IN–41). 2001 PRIUS (RM778U) DI–947 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7SQ–01 PTC Heater Circuit (Heater Radiator) CIRCUIT DESCRIPTION A/C amplifier switches the HTR1 relay and HTR2 relay ON by signal from the A/C amplifier. It supplies power to PTC heater (Heater radiator). 2001 PRIUS (RM778U) DI–948 DIAGNOSTICS – AIR CONDITIONING SYSTEM WIRING DIAGRAM Engine Room R/B No.3 HTR3 Relay 3 3 1 2 3 3 5 3 R–L G R–L P P–B HTR2 Relay 3 G–W 1 3 2 5 3 HTR1 Relay R–L 3 3 1 2 3 5 A/C Amplifier 13 A8 HTR2 P L–R 16 P–B IE1 6 A8 HTR0 3 3 P–B 3 L–Y 3 HTR1 B–R 18 IE1 G–R 3 HTR2 3 1 P2 3 1 P1 P2 HTR3 PTC Heater 3 W 2 P2 3 4 P2 2 P1 Instrument Panel J/B GAUGE 8 2G IG1 Relay 3 2B 3 5 2 1 6 2D 1 2H 8 2K AM1 W–B 5 I15 Ignition SW W–G 2 AM1 IG1 F18 FL Block No.2 MAIN Battery W–B 4 1 IA1 B–Y FL Block No.1 1 F13 W–B 1 1 F13 W–B A A A A F13 DC/DC W–B W–B IA1 W J1 J/C IE J11 J/C ID I18386 2001 PRIUS (RM778U) DI–949 DIAGNOSTICS – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 Check converter circuit (See page DI–934). 2 Check voltage between terminal HTR0, of A/C amplifier and body ground. ON HTR0 (+) (–) I18152 PREPARATION: Remove the center cluster module control with connectors still connected. CHECK: (a) Start engine. (b) Set temperature control switch on ”MAX WARM” position. (c) Set blower switch on ”HI” position. (d) Turn light control switch to OFF. (e) Turn defogger switch OFF. (f) Check voltage between terminal HTR0 of A/C amplifier and body ground at each conditions, as shown in the chart. OK: Condition
Air flow selector: FOOT
Water temp. : Below 60°C (140°F) Below 0.7 V
Air flow selector: FOOT/DEF
Water temp. : Below 50°C (122°F) Below 0.7 V OK NG 2001 PRIUS (RM778U) Voltage Go to step 6. DI–950 DIAGNOSTICS 3 – AIR CONDITIONING SYSTEM Check HTR1 and HTR2 fuses. PREPARATION: Remove the HTR1 and HTR2 fuses from engine room R/B NO. 3. CHECK: Check continuity of HTR1 and HTR2 fuses. OK: Continuity exists. Engine Room R/B No. 3 HTR1 Fuse HTR2 Fuse NG I18396 Check for short in all the harness and components connected to the HTR1 and HTR2 fuses (See attached wiring diagram). OK 4 Check HTR1 and HTR2 relays. 2 1 3 5 3 1 2 5 PREPARATION: Remove the HTR1 and HTR2 relays from engine room relay block NO. 3. CHECK: Check continuity between each pair of terminals shown below of magnetic clutch relay. OK: Z18060 Tester connection Specified condition 1–2 62.5 – 90.9 Ω 3–5 No continuity PREPARATION: Apply battery positive (+) voltage between terminals 1 and 2. CHECK: Check continuity between terminals 3 and 5. OK: Continuity exists. NG OK 2001 PRIUS (RM778U) Replace HTR1 and (or) HTR2 relay. DI–951 DIAGNOSTICS 5 – AIR CONDITIONING SYSTEM Check harness and connector between A/C amplifier and HTR3 fuse (See page IN–41). NG Check and replace harness and connector. OK Check and replace A/C amplifier. 6 Check PTC heater (Heater Radiator). PREPARATION: Remove the heater radiator (See page AC–27). CHECK: Check continuity between terminals of PTC heater connector. OK: Continuity exists. I18395 NG Replace heater radiator. OK Check harness and connector between PTC heater and HTR3 relay, PTC heater and body ground (See page IN–41). 2001 PRIUS (RM778U) DI–952 DIAGNOSTICS – AIR CONDITIONING SYSTEM DI7SR–01 Radiator Fan and Condenser Fan Circuit CIRCUIT DESCRIPTION The electric fan speed is controlled as described below, in accordance with the following signals:
ON/OFF signal of A/C switch
ON/OFF signal detected by the pressure switch (that cut out at medium pressure)
ON/OFF signal detected by water temperature switch 2001 PRIUS (RM778U) DI–953 DIAGNOSTICS – AIR CONDITIONING SYSTEM WIRING DIAGRAM Engine Room J/B A/C Amplifier Fan No.2 Relay 1 2 3 5 10 1J 11 1A 5 1J 3 1K 4 Fan No.1 Relay 1 2 5 3 5 L–W W–B J/C 12 1J 5 1K 2 Fan No.1 Relay CDS FAN 1 A9 RF R–W To Engine ECU 3 1 6 IE1 R–W V–Y E J27 E J27 E J28 V–Y 2 A9 CF A1 A/C Condenser Fan Motor 2 G–W W–G 1K 2 1 V–Y 3 From W 1B DC/DC Fuse 4 From ECU– 1J L–W IG Fuse 7 R1 Radiator Fan Motor 1K 2 1 RDI W–B 2 1 W–B W4 Water Temp. Switch 3 2 W–B A3 A/C Pressure Switch J7 J/C A A A W–B A W–B W–B J1 J/C IE I18401 2001 PRIUS (RM778U) DI–954 DIAGNOSTICS – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminals RF, CF of A/C amplifier and body ground. ON CF (–) RF (+) I18160 PREPARATION: Remove the center cluster module control with connectors still connected. CHECK: (a) Start engine. (b) Turn A/C switch ON. (c) Measure voltage between terminal RF, CF of A/C amplifier and body ground at each conditions as shown in the chart. OK: Terminal Condition Voltage Water temp.: Below 90°C (194 °F) 10 – 14 V Refrigerant pressure: RF ↔ Body Below 1,520 kPa (15.5 kgf/cm2, 220 psi) ground Water temp.: Above 90°C (194 °F) Below 1.0 V Refrigerant pressure: Above 1,520 kPa (15.5 kgf/cm2, 220 psi) CF ↔ Body A/C switch: ON ground A/C switch: OFF OK Go to step 4. NG 2 Check Fan No. 1, No. 2 and No. 3 relays (See page AC–65). NG OK 2001 PRIUS (RM778U) Replace faulty relay Below 1.0 V 10 – 14 V DI–955 DIAGNOSTICS 3 – AIR CONDITIONING SYSTEM Check RDI fuse and CDS fuse. PREPARATION: Remove RDI fuse and CDS fuse from engine room J/B. CHECK: Check continuity of RDI fuse and CDS fuse. OK: Continuity exists. Engine Room J/B RDI Fuse CDS Fuse I18394 NG Check for short in all the harness and components connected to the RDI fuse (See attached wiring diagram). OK Check harness and connector between A/C control amplifier and battery (See page IN–41). 4 Check fan motor operation (See page AC–67). NG Replace fan motor. OK 5 Check pressure switch (See page AC–62). NG OK 2001 PRIUS (RM778U) Replace pressure switch. DI–956 DIAGNOSTICS 6 – AIR CONDITIONING SYSTEM Check engine coolant temp. switch (See page AC–84). NG Replace water temp. switch. OK 7 Check harness and connector between A/C amplifier and pressure switch, pressure switch and body ground (See page IN–41). NG Repair and replace harness and connector. OK 8 Check harness and connector between A/C amplifier and water temp. switch, water temp. switch and body ground (See page IN–41). NG OK Check and replace A/C amplifier. 2001 PRIUS (RM778U) Repair and replace harness and connector. EM–1 ENGINE MECHANICAL – CO/HC CO/HC EM167–04 INSPECTION HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations. 1. INSTALL CONDITIONS (a) Air cleaner installed (b) Air pipes and hoses of air induction system connected (c) All accessories switched OFF (d) All vacuum lines properly connected (e) EFI system wiring connectors fully plugged (f) Ignition timing check correctly (g) Transmission in parking range (h) Tachometer and CO/HC meter calibrated by hand 2. ACTIVATE INSPECTION MODE AND WARM UP ENGINE (See page IN–10) 3. RACE ENGINE AT 2,250 RPM FOR APPROX. 180 SECONDS HINT: At the accelerator opening angle of 60% or more, the engine speed is controlled at 2,250 rpm. 4. A13922 INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING 5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,250 RPM Complete the measuring with 3 minutes. HINT: When doing the 2 mode (idle and 2,250 rpm) test, these measurement order prescribed by the applicable local regulations. 6. STOP ENGINE 2001 PRIUS (RM778U) Author: Date: 1117 EM–2 ENGINE MECHANICAL – CO/HC If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below.
Check heated oxygen sensor operation. (See page DI–44)
See the table below for possible causes, and then inspect and correct the applicable causes if necessary. CO HC Problems Causes Normal High Rough idle 1. Faulty ignitions:
Incorrect timing
Fouled, shorted or improperly gapped plugs
Open or crossed high–tension cords 2. Incorrect valve clearance 3. Leaky intake and exhaust valves 4. Leaky cylinders Low High Rough idle (Fluctuating HC reading) 1. Vacuum leaks:
PCV hoses
Intake manifold
Throttle body 2. Lean mixture causing misfire High High Rough idle (Black smoke from exhaust) 1. Restricted air filter 2. Plugged PCV valve 3. Faulty EFI systems:
Faulty pressure regulator
Defective water temperature sensor
Defective air flow meter
Faulty ECM
Faulty injectors
Faulty throttle position sensor Normal High 1. Faulty HCAC:
Faulty VSV
Faulty actuator 2001 PRIUS (RM778U) Author: Date: 1118 EM–3 ENGINE MECHANICAL – COMPRESSION COMPRESSION EM1IT–02 INSPECTION HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. NOTICE: The measurement of compression pressure should be performed in the Cranking Mode. 1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature. 2. REMOVE AIR CLEANER ASSEMBLY 3. REMOVE IGNITION COIL (See page IG–6) TOYOTA Hand–held Tester 4. 5. (a) (b) (c) DLC3 REMOVE SPARK PLUGS CONNECT TOYOTA HAND–HELD TESTER Connect the TOYOTA hand–held tester to the DLC3. Select the cranking mode on the TOYOTA hand–held tester. Please refer TOYOTA hand–held tester operato’s manual for further details. F12396 6. (a) (b) (c) A13923 INSPECT CYLINDER COMPRESSION PRESSURE Insert a compression gauge into the spark plug hole. Fully open the throttle. While cranking the engine, measure the compression pressure. HINT: In the Cranking Mode, the engine speed is automatically controlled at 250 rpm and the throttle valve is also automatically set in fully–opened condition. (d) Repeat steps (a) through (c) for each cylinder. NOTICE: This measurement must be done in as short a time as possible. Compression pressure: 728 kPa (7.4 kgf/cm2, 106 psi) Minimum pressure: 534 kPa (5.4 kgf/cm2, 77 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less 2001 PRIUS (RM778U) Author: Date: 1119 EM–4 ENGINE MECHANICAL (e) 7. 8. – COMPRESSION If the cylinder compression in one more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression.
If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged.
If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. REINSTALL SPARK PLUGS REINSTALL IGNITION COIL (See page IG–7) 2001 PRIUS (RM778U) Author: Date: 1120 EM–5 ENGINE MECHANICAL – VALVE CLEARANCE VALVE CLEARANCE EM169–02 ADJUSTMENT HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE CYLINDER HEAD COVER (See page EM–15) 2. (a) SET NO.1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align its groove with the timing mark ”0” of the timing chain cover. A11244 (b) Check that both timing marks on the camshaft timing sprocket and valve timing controller assembly are facing right upas shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above. Timing Marks A11245 2 2 3. (a) 1 1 1 1 3 3 A11218 (b) 4 4 3 3 4 4 (c) INSPECT VALVE CLEARANCE Check only the valves indicated.
Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Record the out–of–specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Intake 0.17 – 0.23 mm (0.007 – 0.009 in.) Exhaust 0.27 – 0.33 mm (0.011 – 0.013 in.) Turn the crankshaft 1 revolution (360°) and align the mark as above. (See procedure in step 2) Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a)) 2 2 A11219 2001 PRIUS (RM778U) Author: Date: 1121 EM–6 ENGINE MECHANICAL 4. (a) (b) (c) Matchmarks – VALVE CLEARANCE ADJUST VALVE CLEARANCE Set the No.1 cylinder to the TDC/compression (See procedure in step 2). Place matchmarks on the timing chain and camshaft timing sprockets. Remove the 2 plug from the timing chain cover. A11252 (d) A10471 Using drivers or equipment, while rotating the stopper plate of the tensioner downward, turn the exhaust camshaft right a little and push in the plunger of the chain tensioner as shown in the illustration. HINT: When the stopper plate cannot be lowered easily, rotate the exhaust camshaft right and left a little. (e) Insert a bar of ø 2 – 3 mm (0.08 – 0.12 in.) into the holes in the stopper plate and tensioner to fix the stopper plate. HINT:
At this time, it is easier to fix by installing the bar while rotate the camshaft right and left a little.
Fix the bar with tape so that the bar does not come off. (f) Remove the timing chain from the camshaft timing sprocket. NOTICE:
Never rotate the crankshaft with the timing chain removed.
When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC and align the oil jet hole with the paint mark before rotating it.
When installing the timing chain, make sure to return it to the position of the matchmarks for camshaft and then rotate the crankshaft clockwise to return. HINT: When the chain cannot be removed easily, rotate the intake camshaft right and left a little. (g) Hold the hexagonal portion of the camshaft with a wrench, and remove the bolt and valve timing controller assembly with the chain. NOTICE: Do not disassembled the valve timing controller assembly. (h) Remove the intake and exhaust camshaft assembly. HINT: When disconnect the timing chain from the camshaft timing sprocket, holding the timing chain. 2001 PRIUS (RM778U) Author: Date: 1122 EM–7 ENGINE MECHANICAL – VALVE CLEARANCE (i) Tie the timing chain with a string as shown in the illustration. NOTICE:
Be careful not to drop anything inside the timing chain cover.
Do not allow the chain to come into contact with water or dust. (j) Remove the valve lifters. Valve Lifter A11247 (k) A01082 Determine the replacement valve lifter size according to these Formula or Charts:
Using a micrometer, measure the thickness of the removed lifter.
Calculate the thickness of a new lifter so the valve clearance comes within the specified value. T.......... Thickness of used lifter A......... Measured valve clearance N......... Thickness of new lifter Intake N = T + (A – 0.20 mm (0.008 in.)) Exhaust N = T + (A – 0.30 mm (0.012 in.))
Select a new lifter with a thickness as close as possible to the calculated values. HINT: Lifter are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.). 2001 PRIUS (RM778U) Author: Date: 1123 EM–8 2001 PRIUS (RM778U) Valve Lifter Selection Chart (Intake) ENGINE MECHANICAL – Author: Date: A01234 1124 Intake valve clearance (Cold): 0.15 – 0.25 mm (0.006 – 0.010 in.) EXAMPLE: The 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0157 in.). Replace the 5.250 mm (0.2067 in.) lifter with a new No. 46 lifter. mm (in.) Thickness Lifter No. Thickness 30 5.300 (0.2087) 54 5.540 (0.2181) 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189) 10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197) 12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205) 14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213) 16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220) 18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228) 20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236) 22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244) 24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252) 26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260) 28 5.280 (0.2079) 52 5.520 (0.2173) Thickness Lifter No. 06 5.060 (0.1992) 08 VALVE CLEARANCE New lifter thickness Lifter No. 2001 PRIUS (RM778U) Valve Lifter Selection Chart (Exhaust) ENGINE MECHANICAL – Author: Date: Lifter No. Thickness Lifter No. Thickness 06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181) 08 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189) 10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197) 12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205) 14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213) 16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220) 18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228) 20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236) 22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244) 24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252) 26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260) 28 5.280 (0.2079) 52 5.520 (0.2173) Thickness EM–9 A01235 1125 Exhaust valve clearance (Cold): 0.25 – 0.35 mm (0.010 – 0.014 in.) EXAMPLE: The 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.440 mm (0.0173 in.). Replace the 5.340 mm (0.2102 in.) lifter with a new No. 48 lifter. mm (in.) Lifter No. VALVE CLEARANCE New lifter thickness EM–10 ENGINE MECHANICAL (l) (m) (n) (o) (p) (q) – VALVE CLEARANCE Reinstall the valve lifters (See page EM–43). Align the crankshaft pulley groove with the timing mark ”0” of the timing chain cover. Hold the timing chain, and place the exhaust camshaft and timing sprocket assembly. Align the matchmarks on the timing chain and camshaft timing sprocket. Reinstall the intake camshaft, valve timing controller assembly and camshaft bearing caps (See page EM–45). Remove the bar from the timing chain tensioner. A11246 Timing Marks (r) Check that both timing marks on the camshaft timing sprocket and valve timing controller assembly are facing right upas shown in the illustration. (s) Check that the matchmarks on the timing chain and camshaft timing sprockets. Install a new plug to the timing chain cover. Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) Recheck the valve clearance (See procedure in step 3). Check the valve timing (See page EM–19). REINSTALL CYLINDER HEAD COVER (See page EM–21) A11245 (t) (u) (v) 5. Matchmarks A11252 2001 PRIUS (RM778U) Author: Date: 1126 EM–13 ENGINE MECHANICAL – TIMING CHAIN TIMING CHAIN EM173–04 COMPONENTS 26 (265, 19) Wiper Arm 26 (265, 19) Brake Reservoir Tank Engine Coolant Reservoir Tank Cowl Top Ventilator Lower RH Hood to Cowl Top seal Air Inlet Cowl Top Ventilator Lower LH 7 (71, 62 in. lbf) Air Cleaner Assembly Wiper Motor and Wiper Link Assembly R/B (ABS) Outer Front Cowl Top Panel VSV for EVAP 60 (612, 44) 52 (530, 38) RH Engine Mounting Insulator 52 (530, 38) Engine Under Cover RH N·m (kgf·cm, ft·lbf) : Specified torque A13942 2001 PRIUS (RM778U) Author: Date: 1129 EM–14 ENGINE MECHANICAL – TIMING CHAIN RH Engine Mounting Bracket 55 (561, 41) Ignition Ciol (w/ Igniter) Timing Chain Cover Cylinder Head Cover 10 (100, 7) Pin Crankshaft Pulley 128 (1,300, 94) PCV Hose Front Crankshaft Oil Seal
Gasket 15 (150, 11)
Gasket Water Pump Pulley Chain Tensioner Slipper 11 (110, 8) Water Pump O–Ring Timing Chain Tensioner
Tinming Chain
O–Ring Chain Vibration Damper N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part A13926 2001 PRIUS (RM778U) Author: Date: 1130 EM–15 ENGINE MECHANICAL – TIMING CHAIN EM1IU–03 REMOVAL 1. 3. 4. DISCONNECT BATTERY NEGATIVE (–) TERMINAL AND HV BATTERY SERVICE PLUG (See page HV–1) REMOVE OUTER FR COWL TOP PANEL ASSEMBLY (See page BO–32) REMOVE RH ENGINE UNDER COVER DRAIN ENGINE COOLANT 5. (a) (b) (c) (d) REMOVE AIR CLEANER ASSEMBLY Disconnect the MAF meter connector. Disconnect the EVAP hose from the air cleaner case. Loosen the 2 hose clamps. Remove the 3 bolts and air cleaner assembly. 6. (a) (b) REMOVE BRAKE RESERVOIR TANK Disconnect the brake fluid level sensor connector. Remove the 2 bolts and remove the reservoir tank and suspend it. Remove the 3 bolts and reservoir tank bracket. 2. A13907 (c) A13908 7. (a) (b) (c) (d) (e) (f) A13934 8. 9. 10. 11. A13943 2001 PRIUS (RM778U) DISCONNECT CONNECTORS Disconnect the 4 ignition connectors. Disconnect the 4 injector connectors. Disconnect the 2 VSV connectors. Disconnect the camshaft position sensor connector. Disconnect the water temperature connector. Disconnect the Camshaft timing oil control valve connector. REMOVE AIR INLET REMOVE ENGINE COOLANT RESERVOIR TANK REMOVE VSV FROM ENGINE MOUNTING INSULATOR REMOVE DRIVE BELT EM–16 ENGINE MECHANICAL – TIMING CHAIN 12. REMOVE RH ENGINE MOUNTING INSULATOR (a) Set the jack to the engine. HINT: Place the wooden block between the jack and engine. A13927 (b) Remove the 5 bolts, 2 nuts and RH engine mounting insulator. 13. DISCONNECT ENGINE WIRE FROM CYLINDER HEAD COVER Remove the 3 bolts and disconnect the engine wire from the cylinder head. A13928 14. (a) (b) REMOVE CYLINDER HEAD COVER Remove the ignition coils (See page IG–6) Remove the 2 PCV hoses from the cylinder head cover. (c) Remove the 7 bolts, 2 seal washers, 2 nuts, cylinder head cover and gasket. 15. (a) SET NO.1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align its groove with timing mark ”0” of the timing chain cover. B11761 A11222 A11244 2001 PRIUS (RM778U) EM–17 ENGINE MECHANICAL – TIMING CHAIN (b) Check that both timing marks on the camshaft timing sprocket and valve timing controller assembly are facing right up as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above. Timing Marks A11245 16. (a) SST (b) REMOVE CRANKSHAFT PULLEY Using SST, remove the pulley bolt. SST 09213–70010, 09330–00021 Remove the crankshaft pulley and pin. SST A11253 HINT: If necessary, remove the pulley with SST. SST 09950–50012 (09951–05010, 09952–05010, 09953–05020, 09954–05020) SST A11254 17. REMOVE CRANKSHAFT POSITION SENSOR (See page IG–12) 18. REMOVE RH ENGINE MOUNTING BRACKET Remove the 4 bolts and mounting bracket. 19. REMOVE WATER PUMP (See page CO–6) 20. REMOVE OIL CONTROL VALVE (See page EM–29) A11258 21. (a) (b) (c) A11255 2001 PRIUS (RM778U) REMOVE TIMING CHAIN COVER Remove the 13 bolts and nut. Using a torx wrench socket (E8), remove the stud bolt. Remove the timing chain cover by prying the portions between the cylinder head and cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder head and cylinder block. EM–18 ENGINE MECHANICAL (d) – TIMING CHAIN Remove the 2 O–rings from the cylinder block and oil pan No.1. 22. REMOVE CHAIN TENSIONER Remove the 2 bolts and chain tensioner. 23. REMOVE CHAIN TENSIONER SLIPPER 24. REMOVE CHAIN VIBRATION DAMPER Remove the 2 bolts and damper. 25. REMOVE TIMING CHAIN 2001 PRIUS (RM778U) EM–21 ENGINE MECHANICAL – TIMING CHAIN EM1IV–02 ATDC20° INSTALLATION Mark Link 1. (a) (b) Timing Mark (c) Mark Link INSTALL TIMING CHAIN After setting the crankshaft at ATDC40–140 °, set cams of intake and exhaust timing sprockets at ATDC 20 ° and then the reset the crankshaft at ATDC 20 °. Install the chain vibration damper with the 2 bolts. Torque: 9.0 N·m (92 kgf·cm, 80 in.·lbf) Align the match marks of timing chain mark plate (Yellow), camshaft timing sprocket, camshaft timing gear and crankshaft timing sprocket to install the timing chain as shown in the illustration. HINT: To prevent the exhaust camshaft from spring back turn it using a wrench and set it at the mark on a chain. (d) Install the chain tensioner slipper. 30° Timing Mark A11224 2. (a) (b) (c) A11225 (d) (e) 2001 PRIUS (RM778U) INSTALL CHAIN TENSIONER While rotating the lock plate of the tensioner up–ward, push in the plunger of the tensioner as shown in the illustration. While rotating the lock plate of the tensioner down–ward, insert a bar of 2.5 mm (0.098 in.) into the holes in the lock plate. Install the chain tensioner with the 2 bolts. Torque: 9.0 N·m (92 kgf·cm, 80 in.·lbf) Remove the bar from the chain tensioner. Check that the tension between the intake and exhaust camshaft timing sprocket. EM–22 ENGINE MECHANICAL 3. (a) FIPG FIPG (b) Seal Width: 4 – 5 mm A11260 – TIMING CHAIN INSTALL TIMING CHAIN COVER AND WATER PUMP Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.
Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
Thoroughly clean all components to remove all the loose material.
Using a non–residue solvent, clean both sealing surfaces. Apply seal packing to the timing chain cover as shown in the illustration. Seal packing: Part No. 08826 – 00100 or equivalent
Install a nozzle that has been cut to a 4 – 5 mm (0.16 – 0.20 in.) opening.
FIPG shall be accumulated in the groove for FIPG to a depth of 2.5 mm (0.10 in.) or more. HINT: Avoid applying an excessive amount to the surface.
Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
Immediately remove nozzle from the tube and reinstall cap. (c) Seal Packing Seal Packing Seal Width 4 – 5 mm A11261 2001 PRIUS (RM778U) Apply seal packing to 4 locations as shown in the illustration. Seal packing: Part No. 08826 – 00080 or equivalent
Install a nozzle that has been cut to a 4 – 5 mm (0.16 – 0.20 in.) opening. HINT: Avoid applying an excessive amount to the surface.
Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
Immediately remove nozzle from the tube and reinstall cap. (d) Install 2 new O–rings to the cylinder block and oil pan No. 1. EM–23 ENGINE MECHANICAL – TIMING CHAIN (e) D F B B A A A E G A E G C A A11274 Install the timing chain cover, new O–ring and water pump with the 16 bolts and 3 nuts. Uniformly tighten the bolts and nut in several passes. Torque: Bolt A 11 N·m (113 kgf·cm, 8 ft·lbf) Bolt B 24 N·m (245 kgf·cm, 18 ft·lbf) Bolt C 11 N·m (113 kgf·cm, 8 ft·lbf) Bolt D 24 N·m (245 kgf·cm, 18 ft·lbf) Bolt E 11 N·m (113 kgf·cm, 8 ft·lbf) Nut F 24 N·m (245 kgf·cm, 18 ft·lbf) Nut G 11 N·m (113 kgf·cm, 8 ft·lbf) NOTICE:
Pay attention not to wrap the chain and slipper over the chain cover seal line.
After installing the chain cover, must install the mounting bracket and water pump within 15 minutes. HINT: Each bolt length in indicated in the illustration. A 20 mm (0.787 in.) B 30 mm (1.181 in.) C 35 mm (1.378 in.) D 20 mm (0.787 in.) E 35 mm (1.378 in.) 4. (a) A B 2001 PRIUS (RM778U) A11258 INSTALL RH ENGINE MOUNTING BRACKET Apply seal packing to threads of the mounting bolt. Seal packing: Part No. 08826 – 00080 or equivalent HINT: Do not apply seal packing to 2 or 3 threads of the bolt end. (b) Install the mounting bracket with the 4 bolts. Torque: 55 N·m (561 kgf·cm, 41 ft·lbf) 5. INSTALL CRANKSHAFT POSITION SENSOR Torque: Bolt A 7.5 N·m (76 kgf·cm, 66 in.·lbf) Bolt B 11 N·m (113 kgf·cm, 8 ft·lbf) 6. INSTALL OIL CONTROL VALVE (See page EM–45) Torque: 7.5 N·m (76 kgf·cm, 66 in.·lbf) EM–24 ENGINE MECHANICAL SST SST 7. (a) (b) (c) (d) – TIMING CHAIN INSTALL CRANKSHAFT PULLEY Clean the crankshaft pulley inside. Install the pin to the crankshaft. Align the hole in the crank pulley with the pin position and install the crank pulley. Using SST, install the pulley bolt. SST 09213–70010, 09330–00021 Torque: 128 N·m (1,300 kgf·cm, 94 ft·lbf) A11262 8. (a) (b) Seal Packing B00301 1 4 9 6 10 11 7 3 2 5 8 INSTALL CYLINDER HEAD COVER Remove any old packing (FIPG) material. Apply seal packing to 2 locations as shown in the illustration. Seal packing: Part No. 08826 – 00080 or equivalent Install the gasket to the cylinder head cover. (c) HINT: Part must be assembled within 3 minutes of application. Otherwise the material must be remove and reapplied. (d) Install the cylinder head cover and cable bracket with the 7 bolts, 2 seal washers and 2 nuts. Uniformly tighten the bolts and nuts, in the several passes, in the sequence shown. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) (e) Connect the 2 PCV hoses to the cylinder head cover. 9. CONNECT ENGINE WIRE TO CYLINDER HEAD COVER A11222 10. INSTALL IGNITION COILS (See page IG–7) B11761 11. REMOVE RH ENGINE MOUNTING INSULATOR Install the RH engine mounting insulator with the 5 bolts and 2 nuts. 12. INSTALL VSV TO RH ENGINE MOUNTING INSULATOR 13. INSTALL DRIVE BELT 14. INSTALL ENGINE COOLANT RESERVOIR TANK 15. INSTALL AIR INLET A13928 2001 PRIUS (RM778U) EM–25 ENGINE MECHANICAL 16. (a) (b) (c) (d) (e) (f) – TIMING CHAIN CONNECT CONNECTORS Connect the Camshaft timing oil control valve connector. Connect the water temperature sensor connector. Connect the camshaft position sensor connector. Connect the 2 VSV connectors. Connect the 4 injector connectors. Connect the 4 ignition connectors. A13934 17. (a) (b) (c) (d) 18. 19. A13907 2001 PRIUS (RM778U) INSTALL AIR CLEANER ASSEMBLY Install the air cleaner assembly with the 2 bolts. Tighten the 2 hose clamps. Connect the EVAP hose to the air cleaner case. Connect the MAF meter connector. INSTALL BRAKE RESERVOIR TANK INSTALL OUTER FR COWL TOP PANEL ASSEMBLY (See page BO–35) 20. FILL WITH ENGINE COOLANT 21. INSTALL ENGINE UNDER COVERS 22. CONNECT BATTERY NEGATIVE (–) TERMINAL AND HV BATTERY SERVICE PLUG (See page HV–1) 23. ROAD TEST VEHICLE Check for abnormal noises, shock slippage, correst shift points and smooth operation. 24. RECHECK ENGINE COOLANT AND HV TRANSAXLE COOLANT EM–26 ENGINE MECHANICAL – CYLINDER HEAD CYLINDER HEAD EM1IW–02 COMPONENTS 26 (265, 19) Wiper Arm Brake Reservoir Tank Engine Coolant Reservoir Tank 26 (265, 19) Cowl Top Ventilator Lower RH Hood to Cowl Top Seal Air Inlet Cowl Top Ventilator Lower LH 7 (71, 62 in. lbf) Air Cleaner Assembly VSV for EVAP Wiper Motor and Wiper Link Assembly R/B (ABS) Outer Front Cowl Top Panel 60 (612, 44) 52 (530, 38) RH Engine Mounting Insulator 52 (530, 38) Engine Under Cover RH Front Exhaust Pipe
Gasket 62 (630, 46) N·m (kgf·cm, ft·lbf) : Specified torque A13929 2001 PRIUS (RM778U) Author: Date: 1142 EM–27 ENGINE MECHANICAL – CYLINDER HEAD Heat Insulator 27 (275, 20) Engine Wire Exhaust Manifold
Gasket Ignition Coil (w/ Igniter) PCV Valve Spark Plug Water Temprature Sensor Camshaft Position Sensor Oil Filter Intake Manifold PCV Hose 20 (204, 15)
O–Ring Oil Control Valve Engine Wire
Gasket Throttle Body Assembly 20 (204, 15) Oil Dipstick and Oil Guide N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part A13930 2001 PRIUS (RM778U) Author: Date: 1143 EM–28 ENGINE MECHANICAL – CYLINDER HEAD Cylinder Head Cover 10 (100, 7) RH Engine Mounting Bracket PCV Hose 55 (561, 41) No. 1 Camshaft Bearing Cap Timing Chain Cover No. 2 Camshaft Bearing Cap
Gasket Spring Retainer Camshaft Timing Sprocket Valve Lifter Keeper Crankshaft Pulley Valve Spring Pin Spring Seat 64 (652, 47) Oil Seal Valve Guide Bushing Valve Valve Timing Controller Assembly 128 (1,300, 94) Front Crankshaft Oil Seal 1st: 29.4 (300, 22) 2nd: 90° 3rd: 90° See page EM–45 15 (150, 11)
Gasket Cylinder Head
Gasket 11 (110, 8) Water Pump Pulley Water Pump Chain Tensioner Slipper Timing Chain Tensioner
O–Ring Injector Timing Chain N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part
O–Ring Chain Vibration Damper A13931 2001 PRIUS (RM778U) Author: Date: 1144 EM–29 ENGINE MECHANICAL – CYLINDER HEAD EM1IX–02 REMOVAL 1. 2. 3. 4. 5. DISCONNECT BATTERY NEGATIVE (– )TERMINAL AND HV BATTERY SERVICE PLUG (See page HV–1) REMOVE OUTER FRONT COWL TOP PANEL ASSEMBLY (See page BO–32) DRAIN HV TRANSAXLE COOLANT (See page HT–6) DRAIN ENGINE COOLANT REMOVE CONVERTER AND INVERTER ASSEMBLY (See page HV–18) 6. (a) (b) (c) (d) REMOVE AIR CLEANER ASSEMBLY Disconnect the MAF meter connector. Disconnect the EVAP hose from the air cleaner case. Loosen the 2 hose clamps. Remove the 3 bolts and air cleaner assembly. 7. 8. 9. 10. REMOVE REMOVE REMOVE REMOVE 11. (a) (b) (c) (d) (e) DISCONNECT ENGINE WIRE FROM CYLINDER HEAD Disconnect the ECT sensor connector. Disconnect the camshaft position sensor connector. Disconnect the oil control valve connector. Disconnect the 4 injector connectors. Remove the 3 bolts and disconnect the engine wire protector from the cylinder head cover. A13907 IGNITION COILS (See page IG–6) SPARK PLUGS (See page IG–1) PCV HOSES THROTTLE BODY (See page SF–28) B11761 A13934 2001 PRIUS (RM778U) EM–30 ENGINE MECHANICAL – CYLINDER HEAD 12. REMOVE INTAKE MANIFOLD Remove the 3 bolts, 2 nuts intake manifold and gasket. A13935 13. (a) (b) DISCONNECT FRONT EXHAUST PIPE FROM EXHAUST MANIFOLD Remove the 2 bolts and 2 springs holding the front exhaust pipe to the exhaust manifold. Remove the gasket. A13932 14. REMOVE EXHAUST MANIFOLD STAY Remove the 3 bolts and exhaust manifold stay. A11226 A13933 2001 PRIUS (RM778U) 15. (a) (b) 16. 17. 18. 19. 20. 21. 22. 23. 24. REMOVE EXHAUST MANIFOLD Remove the 4 bolts and upper heat insulator. Remove the 3 bolts 2 nuts, exhaust manifold and gasket. REMOVE CAMSHAFT POSITION SENSOR REMOVE ECT SENSOR REMOVE OIL CONTROL VALVE REMOVE PCV VALVE REMOVE OIL FILLER CAP REMOVE HEAD COVER (See page EM–15) REMOVE INJECTOR (See page SF–11) REMOVE TIMING CHAIN COVER (See page EM–15) REMOVE CAMSHAFT TIMING SPROCKET AND VALVE TIMING CONTROL ASSEMBLY Hold the hexagonal head portion of the camshaft with a wrench, and remove the 2 bolts and timing sprocket and valve timing controller assembly. NOTICE:
Be careful not to damage the cylinder head and valve lifter with the wrench. EM–31 ENGINE MECHANICAL
5 2 9 7 3 3 1 8 4 3 6 A12943 – CYLINDER HEAD Do not disassembly the valve timing controller assembly. 25. REMOVE CAMSHAFTS Uniformly loosen and remove the 19 bearing cap bolts, in several passes, in the sequence shown, and remove the 9 bearing caps, intake and exhaust camshafts. 26. REMOVE CYLINDER HEAD (a) Disconnect the upper radiator hose from the water hose union (b) Disconnect the heater water hose from the water hose union (c) 3 7 9 6 2 1 5 10 8 4 A11228 Using a 8 mm bi–hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown. Remove the 10 cylinder head bolts and plate washers. NOTICE: Head warpage or cracking could result from removing bolts in an incorrect order. (d) Remove the bolt holding the water bypass pipe to the cylinder head. (e) Lift the cylinder head from the dowels on the cylinder block and replace the cylinder head on wooden blocks on a bench. HINT: If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block. A12944 2001 PRIUS (RM778U) EM–33 ENGINE MECHANICAL – CYLINDER HEAD EM16K–03 INSPECTION 1. (a) CLEAN TOP SURFACES OF PISTONS AND CYLINDER BLOCK Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston surface. A01076 (b) Using a gasket scraper, remove all the gasket material from the cylinder block surface. (c) Using compressed air, blow carbon and oil from the bolt holes. CAUTION: Protect your eyes when using high pressure compressed air. A01077 2. REMOVE GASKET MATERIAL Using a gasket scraper, remove all the gasket material from the cylinder block contact surface. NOTICE: Be careful not to scratch the cylinder block contact surface. A01068 3. CLEAN COMBUSTION CHAMBERS Using a wire brush, remove all the carbon from the combustion chambers. NOTICE: Be careful not to scratch the cylinder block contact surface. A01069 4. CLEAN CYLINDER HEAD Using a soft brush and solvent, thoroughly clean the cylinder head. A01070 2001 PRIUS (RM778U) EM–34 ENGINE MECHANICAL – CYLINDER HEAD 5. CLEAN VALVE GUIDE BUSHINGS Using a valve guide bushing brush and solvent, clean all the guide bushings. A01479 6. INSPECT FOR FLATNESS Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder block and the manifolds for warpage. Maximum warpage: Cylinder Block Side Cylinder block side 0.05 mm (0.0020 in.) Intake Manifold side 0.10 mm (0.0394 in.) Exhaust manifold side 0.10 mm (0.0394 in.) If warpage is greater than maximum, replace the cylinder head. Intake Manifold Side Exhaust Manifold Side A01075 7. INSPECT FOR CRACKS Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. A01071 8. (a) (b) EM0580 2001 PRIUS (RM778U) CLEAN VALVES Using a gasket scraper, chip off any carbon from the valve head. Using a wire brush, thoroughly clean the valve. EM–35 ENGINE MECHANICAL 9. (a) – CYLINDER HEAD INSPECT VALVE STEMS AND GUIDE BUSHINGS Using a caliper gauge, measure the inside diameter of the guide bushing. Bushing inside diameter: 5.010 – 5.030 mm (0.19724 – 0.19803 in.) A01478 (b) Z00052 Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: Intake 4.970 – 4.985 mm (0.19567 – 0.19626 in.) Exhaust 4.965 – 4.980 mm (0.19547 – 0.19606 in.) (c) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: Intake 0.025 – 0.060 mm (0.00098 – 0.00236 in.) Exhaust 0.030 – 0.065 mm (0.00118 – 0.00256 in.) Maximum oil clearance: Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) If the clearance is greater than maximum, replace the valve and guide bushing. 10. (a) INSPECT VALVES Check the valve is ground to the correct valve face angle. Valve face angle: 44.5° (b) Check that the surface of the valve for wear. If the valve face is worn, replace the valve. 44.5° EM0180 (c) Check the valve head margin thickness. Standard margin thickness: 1.00 – 1.15 mm (0.0393 – 0.0453 in.) Minimum margin thickness: 0.7 mm (0.028 in.) If the margin thickness is less than minimum, replace the valve. Margin Thickness EM0181 2001 PRIUS (RM778U) EM–36 ENGINE MECHANICAL – CYLINDER HEAD (d) Overall Length EM2534 45° Carbide Cutter Residuary Width Check the valve overall length. Standard overall length: Intake 89.25 mm (3.5138 in.) Exhaust 87.90 mm (3.4606 in.) Minimum overall length: Intake 88.95 mm (3.5020 in.) Exhaust 87.60 mm (3.4488 in.) If the overall length is less than minimum, replace the valve. (e) Check the surface of the valve stem tip for wear. If the valve stem tip is worn, replace the valve. 11. INSPECT AND CLEAN VALVE SEATS (a) Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats. Resurface A01073 (b) Width A01074 20° 45° 1.0 – 1.4 mm EM0185 (2) 75° 45° 1.0 – 1.4 mm 2001 PRIUS (RM778U) Check the valve seating position. Apply a light coat of prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Do not rotate valve. (c) Check the valve face and seat for the following:
If blue appears 360° around the face, the valve is concentric. If not, replace the valve.
If blue appears 360° around the valve seat, the guide and face are concentric. If not, resurface the seat.
Check that the seat contact is in the middle of the valve face with the following width: 1.0 – 1.4 mm (0.039 – 0.055 in.) If not, correct the valve seats as follows: (1) If the seating is too high on the valve face, use 20° and 45° cutters to correct the seat. EM0186 If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat. EM–37 ENGINE MECHANICAL (d) (e) – CYLINDER HEAD Hand–lap the valve and valve seat with an abrasive compound. After hand–lapping, clean the valve and valve seat. A01072 12. (a) INSPECT VALVE SPRINGS Using a steel square, measure the deviation of the valve spring. Maximum deviation: 1.6 mm (0.063 in.) Maximum angle (reference): 2° If the deviation is greater than maximum, replace the valve spring. Deviation EM0988 (b) Using vernier calipers, measure the free length of the valve spring. Free length: 59.77 mm (2.353 in.) If the free length is not as specified, replace the valve spring. EM0801 (c) EM0281 EM1628 2001 PRIUS (RM778U) Using a spring tester, measure the tension of the valve spring at the specified installed length. Installed tension: 140 – 154 N (14.3 – 15.7 kgf, 31.5 – 34.6 lbf) at 32.5 mm (1.280 in.) Maximum working tension: 180 – 198 N (18.4 – 20.2 kgf, 40.4 – 44.8 lbf) at 25.1 mm (0.988 in.) If the installed tension is not as specified, replace the valve spring 13. INSPECT CAMSHAFT FOR RUNOUT (a) Place the camshaft on V–blocks. (b) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than maximum, replace the camshaft. EM–38 ENGINE MECHANICAL EM2011 – CYLINDER HEAD 14. INSPECT CAM LOBES Using a micrometer, measure the cam lobe height. Standard cam lobe height: Intake 42.310 – 42.410 mm (1.62637 – 1.66968 in.) Exhaust 44.046 – 44.146 mm (1.73409 – 1.73803 in.) Minimum cam lobe height: Intake 42.16 mm (1.6598 in.) Exhaust 43.90 mm (1.7283 in.) If the cam lobe height is less than minimum, replace the camshaft. 15. INSPECT CAMSHAFT JOURNALS Using a micrometer, measure the journal diameter. No.1 journal diameter: 34.449 – 34.465 mm (1.35626 – 1.35689 in.) Others journal diameter: 22.949 – 22.965 mm (0.90350 – 0.90413 in.) If the journal diameter is not as specified, check the oil clearance. EM2538 16. (a) (b) (c) Plastigage INSPECT CAMSHAFT JOURNAL CLEARANCE Clean the bearing caps and camshaft journals. Place the camshafts on the cylinder head. Lay a strip of Plastigage across each of the camshaft journal. A01452 (d) Install the bearing caps (See page EM–45). Torque: No.1 23 N·m (235 kgf·cm, 17 ft·lbf) No.2 12.7 N·m (130 kgf·cm, 10 ft·lbf) NOTICE: Do not turn the camshaft. (e) Remove the bearing caps. A12943 (f) A01453 2001 PRIUS (RM778U) Measure the plastigage at its widest point. Standard oil clearance: 0.040 – 0.095 mm (0.00157 – 0.00374 in.) Maximum oil clearance: 0.115 mm (0.00453 in.) If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. (g) Completely remove the Plastigage. (h) Remove the camshafts. EM–39 ENGINE MECHANICAL – CYLINDER HEAD 17. (a) (b) A01455 INSPECT CAMSHAFT THRUST CLEARANCE Install the camshafts (See page EM–45). Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.040 – 0.095 mm (0.0016 – 0.0037 in.) Maximum thrust clearance: 0.11 mm (0.0043 in.) If the thrust clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. (c) Remove the camshafts. 18. (a) INSPECT VALVE LIFTERS AND LIFTER BORES Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 31.009 – 31.025 mm (1.22082 – 1.22145 in.) A13949 (b) P16860 2001 PRIUS (RM778U) Using a micrometer, measure the lifter diameter. Lifter diameter: 30.966 – 30.976 mm (1.21913 – 1.21953 in.) (c) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.031 – 0.059 mm (0.00122 – 0.00232 in.) Maximum oil clearance: 0.1 mm (0.004 in.) If the oil clearance is greater than maximum, replace the lifter. If necessary, replace the cylinder head. EM–40 ENGINE MECHANICAL – CYLINDER HEAD 19. INSPECT INTAKE MANIFOLD Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.10 mm (0.0039 in.) If warpage is greater than maximum, replace the manifold. A13936 20. INSPECT EXHAUST MANIFOLD Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.70 mm (0.0276 in.) If warpage is greater than maximum, replace the manifold. A13937 2001 PRIUS (RM778U) EM–41 ENGINE MECHANICAL – CYLINDER HEAD EM16L–02 REPLACEMENT 80 – 100°C REPLACE VALVE GUIDE BUSHINGS (a) Gradually heat the cylinder head to 80 – 100°C (176 – 212°F). A01067 (b) Using SST and a hammer, tap out the guide bushing. SST 09201–01055, 09950–70010 (09951–07100) (c) Using a caliper gauge, measure the bushing bore diameter of the cylinder head. SST A01066 A13949 Both intake and exhaust Bushing bore diameter mm (in.) Bushing size 9.685 – 9.706 (0.38130 – 0.38213) Use STD 9.735 – 9.756 (0.38327 – 0.38493) Use O/S 0.05 (f) SST A01446 2001 PRIUS (RM778U) (d) Select the new guide bushing (STD or O/S 0.05). If the bushing bore diameter of the cylinder head is greater than 9.706 mm (0.38213 in.), machine the bushing bore to the following dimension: 9.735 – 9.756 mm (0.38327 – 0.38493 in.) If the bushing bore diameter of the cylinder head is greater than 9.756 mm (0.38493 in.), replace the cylinder head. (e) Gradually heat the cylinder head to 80 – 100°C (176 – 212°F). Using SST and a hammer, tap in a new guide bushing to the specified protrusion height. SST 09201–01055, 09950–70010 (09951–07100) Protrusion height: 9.0 – 9.4 mm (0.354 – 0.370 in.) EM–42 ENGINE MECHANICAL (g) A01447 2001 PRIUS (RM778U) – CYLINDER HEAD Using a sharp 5 mm reamer, ream the guide bushing to obtain the standard specified clearance (See page EM–33) between the guide bushing and valve stem. EM–43 ENGINE MECHANICAL – CYLINDER HEAD EM16M–02 REASSEMBLY HINT:


1. INSTALL WATER HOSE UNIONS HINT: When using a new cylinder head, water hose unions must be installed. (a) Mark the standard position away from the edge, onto the water hose union. 18 mm 15 mm Thoroughly clean all parts to be assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. Replace oil seals with new ones. For Radiator Hose For Water Bypass Hose A11230 (b) Adhesive Apply adhesive to the water hose union hole of the cylinder head. Adhesive: Part No.08833–00070, THREE BOND 1324 or equivalent A11231 (c) Using a press, press in a new water hose union until there is protruding from the cylinder head. Standard protrusion: A 29 mm (1.14 in.) B 44 mm (1.73 in.) NOTICE: Avoid pressing a new water hose union in too far by measuring the amount of protrusion while pressing. B A A11232 2. (a) SST A01063 2001 PRIUS (RM778U) INSTALL VALVES Using SST, push in a new oil seal. SST 09201–41020 EM–44 ENGINE MECHANICAL Intake – CYLINDER HEAD HINT: The intake valve oil seal is light brown and the exhaust valve oil seal is gray. NOTICE: Pay much attention assembling the oil seal for intake and exhaust. Assembling the wrong one may cause a failure. Exhaust Mark ”NOK” Gray Surface Light Brown Surface S05923 (b) Install the valve (1), spring (2), valve spring (3), and spring retainer (4). (c) Using SST, compress the valve spring and place the 2 keepers around the valve stem. SST 09202–70020 (09202–00010) (1) (3) (4) (2) A01065 SST A01061 (d) Using a plastic–faced hammer and the valve stem (not in use) tip wound with vinyl tape, lightly tap the valve stem tip to ensure a proper fit. NOTICE: Be careful not to damage the valve stem tip. 3. INSTALL VALVE LIFTERS (a) Install the valve lifter. (b) Check that the valve lifter rotates smoothly by hand. A07307 2001 PRIUS (RM778U) EM–45 ENGINE MECHANICAL – CYLINDER HEAD EM1IY–02 INSTALLATION HINT:


Thoroughly clean all parts to be assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. Replace all gaskets and oil seals with new ones. 1. (a) PLACE CYLINDER HEAD ON CYLINDER BLOCK Place a new cylinder head gasket on the cylinder block surface with the Lod No. stamp upward. NOTICE: Be careful of the installation direction. (b) Place the cylinder head quietly in order not to damage the gasket with the bottom part of the head. Lod No. A11249 8 4 2 5 9 10 6 1 3 7 A11228 90° 2. INSTALL CYLINDER HEAD BOLTS HINT:
The cylinder head bolts are tightened in 2 progressive steps (steps (b) and (d)).
If any cylinder head bolt is broken or deformed, replace it. (a) Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts. (b) Using a 10 mm bi–hexagon wrench, install and uniformly tighten the 10 cylinder head bolts and plate washers, in several passes, in the sequence shown. Torque: 29.4 N·m (300 kgf·cm, 22 ft·lbf) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. (c) (d) 90° Front (e) (f) A12126 2001 PRIUS (RM778U) Mark the front of the cylinder head bolt with paint. Retighten the cylinder head bolts by 90° and 90° in the numerical order shown. Check that the paint mark is now at a 180° angle to the front. Install the bolt holding the water bypass pipe to the cylinder head. Torque: 9.0 N·m (92 kgf·cm, 80 in.·lbf) EM–46 ENGINE MECHANICAL (g) (h) 3. (a) No.1 Cam Lobe – CYLINDER HEAD Connect the upper radiator hose to the water hose unions. Connect the heater hose to the water hose unions. INSTALL CAMSHAFTS Place the 2 camshafts on the cylinder head with the No.1 cam lobes facing as shown the illustration. A12945 (b) Install the bearing caps in their proper locations. HINT: No. 2 camshaft bearing cap has a number and front mark. (c) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. A12946 (d) 7 3 1 5 9 9 8 4 2 6 9 A12943 2001 PRIUS (RM778U) Install and uniformly tighten the 19 bearing cap bolts. After tightening the No.1 camshaft bearing cap, tighten then in several passes, in the sequence shown. Torque: No. 1 23 N·m (235 kgf·cm, 17 ft·lbf) No. 2 12.7 N·m (130 kgf·cm, 10 ft·lbf) 4. INSTALL VALVE TIMING CONTROLLER ASSEMBLY AND CAMSHAFT TIMING SPROCKET (a) Apply engine oil in the rage from the tip of the intake camshaft to 16 mm from that tip. (b) Except leaded gasoline spec: Align the timing mark on the valve timing controller assembly with the knock pin, and install the value timing controller assembly to the camshaft. NOTICE: Do not push valve timing controller assembly to the camshaft forcibly when installing it. (c) Align the knock pin hole in the camshaft timing sprocket with the knock pin of the camshaft, and install the sprocket to the camshaft. EM–47 ENGINE MECHANICAL (d) (e) 5. 6. 7. 8. 9. 10. 11. 12. 13. (a) (b) – CYLINDER HEAD Temporarily install the timing sprocket bolt. Hold the hexagon head portion of the camshaft with a wrench, and install the bolt. Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) CHECK AND ADJUST VALVE CLEARANCE (See page EM–5) INSTALL CYLINDER HEAD COVER (See page EM–21) INSTALL OIL CONTROL VALVE INSTALL OIL FILTER CAP INSTALL PCV VALVE INSTALL ECT SENSOR (See page SF–49) INSTALL CAMSHAFT POSITION SENSOR (See page IG–10) INSTALL TIMING CHAIN COVER (See page EM–21) INSTALL EXHAUST MANIFOLD Install a new gasket and the exhaust manifold with the 3 bolts 2 nuts. Uniformly tighten the bolts and nuts in several passes. Torque: 27 N·m (275 kgf·cm, 20 ft·lbf) Install the upper heat insulator with the 4 bolts. Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf) A13933 14. INSTALL EXHAUST MANIFOLD STAY Install the manifold stay with the 3 bolts. Alternately tighten the bolts. Torque: 37 N·m (377 kgf·cm, 27 ft·lbf) A11226 15. (a) (b) A13932 2001 PRIUS (RM778U) CONNECT FRONT EXHAUST PIPE TO EXHAUST MANIFOLD Place a new gasket to the exhaust manifold. Install the 2 bolts and 2 springs holding the front exhaust pipe to the exhaust manifold. Torque: 62 N·m (630 kgf·cm, 46 ft·lbf) EM–48 ENGINE MECHANICAL – CYLINDER HEAD 16. INSTALL INTAKE MANIFOLD Install a new gasket, the intake manifold and 2 brackets with the 2 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes. Torque: 20 N·m (204 kgf·cm, 15 ft·lbf) A13935 17. (a) 21. CONNECT ENGINE WIRE TO CYLINDER HEAD Install the engine wire protector to the cylinder head cover with the 2 bolts. Connect the water ECT sensor connector. Connect the camshaft position sensor connector. Connect the oil control valve connector. Connect the 4 injector connectors. INSTALL THROTTLE BODY (See page SF–31) INSTALL PCV HOSES INSTALL SPARK PLUGS (See page IG–1) INSTALL IGNITION COILS (See page IG–7) 22. (a) (b) (c) (d) INSTALL AIR CLEANER ASSEMBLY Install the air cleaner assembly with the 2 bolts. Tighten the 2 hose clamps. Connect the EVAP hose to the air cleaner case. Connect the MAF meter connector. 23. INSTALL CONVERTER AND INVERTER ASSEMBLY (See page HV–18) INSTALL OUTER FR COWL TOP PANEL ASSEMBLY (See page BO–32) FILL WITH ENGINE COOLANT FILL WITH HV COOLANT INSTALL ENGINE UNDER COVERS CONNECT BATTERY NEGATIVE (–) TERMINAL AND HV BATTERY SERVICE PLUG (See page HV–1) (b) (c) (d) (e) 18. A13934 19. 20. A13907 24. 25. 26. 27. 28. 2001 PRIUS (RM778U) EM–49 ENGINE MECHANICAL – CYLINDER HEAD 29. ROAD TEST VEHICLE Check for abnormal noises, shock slippage, correct shift points and smooth operation. 30. RECHECK ENGINE COOLANT AND HV COOLANT 2001 PRIUS (RM778U) EM–50 ENGINE MECHANICAL – ENGINE UNIT ENGINE UNIT EM1IZ–02 COMPONENTS 26 (265, 19) Wiper Arm 26 (265, 19) Cowl Top Ventilator Lower RH Hood to Cowl Top Seal Cowl Top Ventilator Lower LH Brake Reservoir Tank Engine Coolant Reservoir Tank 7 (71, 62 in. lbf) Wiper Motor and Wiper Link Assembly Air Inlet R/B (ABS) Outer Front Cowl Top Panel Air Cleaner Assembly Head Light RH 11.5 (117, 8) Front Bumper Engine Under Cover N·m (kgf·cm, ft·lbf) : Specified torque A13904 2001 PRIUS (RM778U) Author: Date: 1166 EM–51 ENGINE MECHANICAL – ENGINE UNIT Converter and Inverter Assembly Engine Mounting Insulator RH Fuel Tube 52 (530, 38) Shift Lever Cable Drive Belt 80 (816, 59) A/C Compressor Engine Mounting Insulator LH 25 (255, 18)
Gasket Vacuum Hose for HCAC 62 (630, 46) RH Drive Shaft 43 (440, 32) Front Exhaust Pipe 62 (630, 46)
Gasket Intermediate Extension
LH Drive Shaft
Torque Rod
100 (1,020, 74) 216 (2,203, 159) 157 (1,601, 116) 60 (612, 74) 113 (1,152, 83) 142 (1,448, 105) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part A13905 2001 PRIUS (RM778U) Author: Date: 1167 EM–52 ENGINE MECHANICAL – ENGINE UNIT Engine Unit Fly Wheel Damper Disc x6 Damper Disc Spring x6 16 (163, 12)
1st: 49 (500, 36) 2nd: 90° See page EM–58 Transaxle 33 (337, 24) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part A13906 2001 PRIUS (RM778U) Author: Date: 1168 EM–53 ENGINE MECHANICAL – ENGINE UNIT EM1J0–02 REMOVAL 1. 2. 3. 4. 5. 6. DISCONNECT BATTERY NEGATIVE (–) TERMINAL AND HV BATTERY SERVICE PLUG (See page HV–1) REMOVE OUTER FRONT COWL TOP PANEL ASSEMBLY (See page BO–32) DRAIN HV COOLANT (See page HT–8) DRAIN ENGINE COOLANT REMOVE CONVERTER AND INVERTER ASSEMBLY (See page HV–18) REMOVE HEATER UNIT WATER PUMP (See page AC–55) 7. (a) (b) (c) (d) REMOVE AIR CLEANER ASSEMBLY Disconnect the MAF meter connector. Disconnect the EVAP hose from the air cleaner case. Loosen the 2 hose clamps. Remove the 2 bolts and air cleaner assembly. 8. (a) (b) (c) (d) (e) (f) (g) 9. 10. 11. 12. DISCONNECT CONNECTORS, CLAMPS AND HOSES Disconnect the engine wire clamps. Disconnect the heated oxygen sensor connector. Disconnect the 2 power steering connectors. Disconnect the VSV connector for purge line. Disconnect the VSV hose for purge line. Disconnect the ground strap from RH fender apron. Disconnect the ground strap from LH fender apron. REMOVE AIR INLET REMOVE ENGINE COOLANT RESERVOIR TANK DISCONNECT 2 RADIATOR HOSES FROM RADIATOR DISCONNECT HEATER HOSE FROM CYLINDER BLOCK A13907 A13943 2001 PRIUS (RM778U) EM–54 ENGINE MECHANICAL – ENGINE UNIT 13. 14. (a) (b) DISCONNECT SHIFT LEVER CABLE REMOVE BRAKE RESERVOIR TANK Disconnect the brake fluid level sensor connector. Remove the 2 bolts and remove the reservoir tank and suspend it. 15. (a) (b) DISCONNECT ENGINE WIRE FROM CABIN Remove the ECM (See page SF–63). Disconnect the grommet from the cowl panel, and pull out the engine wire. REMOVE J/B NO. 1 FROM RH FENDER APRON A13908 16. A13938 17. DISCONNECT FUEL TUBE Disconnect the fuel tube from the fuel pump. 18. REMOVE DRIVE BELT 19. REMOVE ENGINE UNDER COVERS A13909 20. (a) (b) REMOVE A/C COMPRESSER Disconnect the A/C compresser connector. Remove the 4 bolts and disconnect the A/C compresser from the engine. HINT: Suspend the A/C compresser securely. 21. DISCONNECT INTERMEDIATE EXTENSION FROM STEERING ASSEMBLY (See page SR–6) I18009 22. (a) (b) (c) A13932 2001 PRIUS (RM778U) REMOVE EXHAUST PIPE Disconnect the heated oxygen sensor from the exhaust pipe. Remove the 2 springs and 3 bolts. Disconnect the 2 O–rings, and remove the exhaust pipe and 2 gaskets. EM–55 ENGINE MECHANICAL – ENGINE UNIT 23. DISCONNECT TIE ROD END FROM STEERING KNUCKLE (See page SA–9) 24. DISCONNECT STABILIZER BAR LINK Remove the nut and disconnect the stabilizer bar link from the suspension member. 25. DISCONNECT BALL JOINT FROM LOWER ARM Remove the 2 bolts and 4 nuts, disconnect the ball joint. 26. REMOVE DRIVE SHAFTS (See page SA–17) A13910 27. REMOVE TORQUE ROD Remove the 4 bolts and 2 nuts and torque rod from the body. A13911 28. REMOVE SUSPENSION MEMBER Remove the 4 bolts and disconnect the suspension member from the body. A13912 29. SET ENGINE JACK NOTICE: Using chain, hold the engine tightly. A13913 30. (a) A13914 2001 PRIUS (RM778U) DISCONNECT ENGINE MOUNTINGS Remove the 2 bolts, 2 nuts and disconnect the RH engine mounting insulator from the bracket. EM–56 ENGINE MECHANICAL (b) – ENGINE UNIT Remove the nut and disconnect the LH engine mounting from the insulator. A13915 A13916 SST 31. REMOVE ENGINE AND TRANSAXLE ASSEMBLY (a) Lower the engine out of vehicle slowly and carefully. NOTICE: Make sure the engine is clear of all wiring, hoses and cables. (b) Using a engine sliding device, and place the engine and transaxle assembly onto the stand. 32. SEPARATE ENGINE AND TRANSAXLE (a) Remove the 2 bolts and dust cover. (b) Remove the 6 bolts and transaxle from the engine. 33. REMOVE DAMPER DISC Using SST, hold the crankshaft pulley, remove the 6 bolts and damper disc and spring. SST 09213–58012 (91111–580845), 09330–00021 SST A13917 34. REMOVE FLYWHEEL Using SST, hold the crankshaft pulley, remove the 6 bolts and flywheel. SST 09213–58012 (91111–580845), 09330–00021 SST SST A13918 2001 PRIUS (RM778U) EM–58 ENGINE MECHANICAL – ENGINE UNIT EM1J2–02 INSTALLATION 1. (a) INSTALL FLYWHEEL Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Part No. 08833–00070, THREE BOND 1324 or equivalent (b) Install and uniformly tighten the new 6 bolts in several passes, in the sequence shown. Torque: 84 N·m (857 kgf·cm, 62 ft·lbf) Retighten the flywheel bolts by 90° in the numerical order shown. P08755 (c) 3 1 5 6 2 4 SST SST A13917 2. (a) SST A13940 1 3 6 SST SST HINT: Take care not to insert damper disc in the wrong direction. (b) Set the damper spring on the damper disc. (c) Following the procedures shown in the illustration, tighten the 6 bolts in the order starting the bolt locating near the knock pin on the top. Torque: 16 N·m (163 kgf·cm, 12 ft·lbf) HINT:
Following the order in the illustration, tighten the bolts at a time evenly.
Move SST up and down, right and left lightly, after checking that the disc in the center, tighten the bolts. 5 4 2 A13917 3. (a) (b) (c) 2001 PRIUS (RM778U) INSTALL DAMPER DISC Insert SST in the damper disc, then insert them in the flywheel. SST 09301–00110 INSTALL TRANSAXLE TO ENGINE Attach the transaxle to the engine, and install the 6 bolts. Torque: 33 N·m (337 kgf·cm, 24 ft·lbf) Install the dust cover. Install the LH engine mounting bracket. Torque: 52 N·m (530 kgf·cm, 38 ft·lbf) EM–59 ENGINE MECHANICAL – ENGINE UNIT 4. SET ENGINE JACK NOTICE: Using a chain, hold the engine tightly. 5. INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN VEHICLE (a) Raise the engine into the engine compartment. (b) Keep the engine level, and align RH and LH mountings with the insulator. A13913 (c) (d) Connect the LH mounting bracket to the insulator with the nut. Torque: 80 N·m (816 kgf·cm, 59 ft·lbf) Connect the RH mounting bracket to the insulator with the 2 bolts and 2 nuts. Torque: 52 N·m (530 kgf·cm, 38 ft·lbf) A13914 B A B 6. INSTALL SUSPENSION MEMBER Connect the suspension member with the 4 bolts. Torque: Bolt A: 113 N·m (1,152 kgf·cm, 83 ft·lbf) Bolt B: 157 N·m (1,601 kgf·cm, 116 ft·lbf) A A13912 7. (a) (b) 8. INSTALL TORQUE ROD Install the torque rod through bolt and nut. Torque: 100 N·m (1,020 kgf·cm, 74 ft·lbf) Install the 2 bolts. Torque: 60 N·m (612 kgf·cm, 44 ft·lbf) INSTALL DRIVE SHAFTS (See page SA–23) A13911 9. 10. 11. A13910 2001 PRIUS (RM778U) CONNECT BALL JOINT TO LOWER ARM Torque: 142 N·m (1,448 kgf·cm, 105 ft·lbf) CONNECT STABILIZER BAR LINK Torque: 74 N·m (755 kgf·cm, 55 ft·lbf) CONNECT TIE ROD END TO STEERING KNUCKLE (See page SA–14) EM–60 ENGINE MECHANICAL 12. (a) (b) A13939 (c) (d) 13. (a) – ENGINE UNIT INSTALL EXHAUST PIPE Install the 2 gaskets to the exhaust pipe and connect the 2 O–rings. Install the 2 springs and 3 bolts. Torque: Front exhaust pipe: 62 N·m (630 kgf·cm, 46 ft·lbf) Tailpipe: 32 N·m (326 kgf·cm, 24 ft·lbf) Connect the hose to the actuator. Connect the heated oxygen sensor. 15. INSTALL A/C COMPRESSER Connect the A/C compresser to the engine with the 4 bolts. Torque: 25 N·m (255 kgf·cm, 18 ft·lbf) Connect the A/C compresser connector. CONNECT INTERMEDIATE EXTENSION STEERING ASSEMBLY (See page SR–14) INSTALL DRIVE BELT (See page SA–23) 16. 17. CONNECT FUEL TUBE INSTALL J/B NO. 1 TO RH FENDER APRON 18. (a) CONNECT ENGINE WIRE TO CABIN Pull in the engine wire to the cowk panel and connect the grommet. Connect the ECM connectors. Install the ECM (See page SF–63). INSTALL BRAKE RESERVOIR TANK Install the reservoir tank with the 2 bolts. Connect the brake fluid level sensor connector. CONNECT SHIFT LEVER CABLE TO TRANSAXLE CONNECT HEATER HOSE TO CYLINDER BLOCK CONNECT 2 RADIATOR HOSES TO RADIATOR INSTALL ENGINE COOLANT RESERVOIR TANK INSTALL AIR INLET (b) 14. I18009 A13909 A13938 2001 PRIUS (RM778U) (b) (c) 19. (a) (b) 20. 21. 22. 23. 24. EM–61 ENGINE MECHANICAL 25. (a) (b) (c) (d) (e) (f) (g) – ENGINE UNIT CONNECT CONNECTORS, CLAMPS AND HOSES Connect the Ground strap from LH fender apron. Connect the Ground strap from RH fender apron. Connect the VSV hose for purge line. Connect the VSV connector for purge line. Connect the 2 power steering connectors. Connect the Heated oxygen sensor connector. Connect the Engine wire clamps. A13943 26. (a) (b) (c) (d) 27. A13907 2001 PRIUS (RM778U) INSTALL AIR CLEANER ASSEMBLY Install the air cleaner assembly with the 2 bolts. Tighten the 2 hose clamps. Connect the EVAP hose to the air cleaner case. Connect the MAF meter connector. INSTALL HEATER UNIT WATER PUMP (See page AC–55) 28. INSTALL CONVERTER AND INVERTER ASSEMBLY (See page HV–22) 29. INSTALL OUTER FR COWL TOP PANEL ASSEMBLY (See page BO–35) 30. FILL WITH ENGINE COOLANT 31. FILL WITH HV COOLANT 32. INSTALL ENGINE UNDER COVERS 33. CONNECT BATTERY NEGATIVE (–) TERMINAL AND HV BATTERY SERVICE PLUG (See page HV–1) 34. ROAD TEST VEHICLE Check for abnormal noiss, shock slippage, correct shift points and smooth operation. 35. RECHECK ENGINE COOLANT AND HV TRANSAXLE COOLANT EM–62 ENGINE MECHANICAL – CYLINDER BLOCK CYLINDER BLOCK EM17B–02 COMPONENTS Water Bypass Pipe 9.0 (90, 80 in.·lbf) 9.0 (90, 80 in.·lbf) 9.0 (90, 80 in.·lbf)  Gasket
Engine Coolant Drain Union Knock Sensor Oil Pressure Switch  Gasket 9.0 (90. 80 in.·lbf) Thermostat Water Inlet N·m(kgf·cm, ft·lbf) : Specified torque Non–reusable part
Precoated part A11250 2001 PRIUS (RM778U) Author: Date: 1178 EM–63 ENGINE MECHANICAL – CYLINDER BLOCK No.1 Compression Ring No.2 Compression Ring Oil Ring Connecting Rod Piston Connecting Rod Bearing Piston Pin Connecting Rod Cap See page EM–78 1st 15 (150,11) 2nd Turn 90° Cylinder Block Upper Main Bearing Crankshaft Thrust Washer  O–ring Crankshaft Thrust Washer  Crankshaft Rear Oil Seal Crankshaft Lower Main Bearing Crankshaft Bearing Cap See page EM–78 1st 22 (220,16) 2nd Turn 90°  O–ring x10 Oil Pan No.1  Gasket Oil Filter Union 30 (306, 22)  O–ring Oil Filter x10 Oil Pan No.2 24 (245, 18) Oil strainer 11 (112, 8) 38 (387, 28)  Gasket 9.0 (92, 80 in.·lbf) N·m(kgf·cm, ft·lbf) : Specified torque Non–reusable part A14341 2001 PRIUS (RM778U) Author: Date: 1179 EM–64 ENGINE MECHANICAL – CYLINDER BLOCK EM17C–04 DISASSEMBLY 1. 2. 3. 4. A10451 INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY REMOVE TIMING CHAIN (See page EM–15) REMOVE CYLINDER HEAD (See page EM–29) REMOVE ENGINE WIRE 5. REMOVE WATER BYPASS PIPE Remove the 2 nuts, bolt and water bypass pipe. 6. REMOVE THERMOSTAT (See page CO–10) 7. REMOVE KNOCK SENSOR (See page SF–56) 8. REMOVE OIL PRESSURE SWITCH (See page LU–1) 9. REMOVE ENGINE COOLANT DRAIN UNION 10. REMOVE OIL FILTER (See page LU–3) 11. REMOVE OIL FILTER UNION Using a 12 mm hexagon wrench, remove the oil filter union. A11268 12. (a) (b) A11269 A14342 2001 PRIUS (RM778U) REMOVE OIL PAN NO. 2 Remove the 9 bolts and 2 nuts. Insert the blade of SST between the oil pan No. 1 and oil pan No. 2, and cut off applied sealer and remove the oil pan. SST 09032–00100 NOTICE:
Be careful not to the damage the oil pan contact surface of the oil pan No. 1.
Be careful not to damage the oil pan No. 2 flange. 13. REMOVE OIL STRAINER Remove the bolt and 2 nuts, oil strainer and gasket. EM–65 ENGINE MECHANICAL – CYLINDER BLOCK 14. (a) REMOVE OIL PAN NO. 1 Uniformly loosen and remove the 13 bolts, in several passes, in the sequence shown. (b) Using screwdriver remove the oil pan No. 1 by prying the portions between the cylinder block and oil pan No. 1. Remove the 2 O–rings from the cylinder block. A11271 (c) A11272 A10452 15. CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.16 – 0.36 mm (0.0063 – 0.0142 in.) Maximum thrust clearance: 0.36 mm (0.0142 in.) If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft. 16. REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE (a) Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly. (b) Remove the 2 connecting rod cap bolts. A10453 (c) A10454 2001 PRIUS (RM778U) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. HINT: Keep the lower bearing inserted with the connecting rod cap. (d) Clean the crank pin and bearing. (e) Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. EM–66 ENGINE MECHANICAL (f) Plastigage – CYLINDER BLOCK Lay a strip of Plastigage the crank pin. A10455 (g) Install the connecting rod cap with the 2 bolts. (See page EM–78) Torque: 1ST 15 N·m (150 kgf·cm, 11 ft·lbf) 2ND Turn 90 ° NOTICE: Do not turn the crankshaft. A10456 (h) A10457 Mark 1, 2 or 3 Remove the 2 bolts, connecting rod cap and lower bearing. (See procedure (b) and (c) above) (i) Measure the Plastigage at its widest point. Standard oil clearance: 0.016 – 0.040 mm (0.0006 – 0.0016 in.) Maximum oil clearance: 0.06 mm (0.0024 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft. HINT: If replacing a bearing, replace it with one having the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked ”1”, ”2” and ”3” accordingly. Reference Standard bearing center wall thickness Mark Mark 1, 2 or 3 A01198 (j) 2001 PRIUS (RM778U) mm (in.) ”1” 1.488 – 1.492 (0.0586 – 0.0587) ”2” 1.492 – 1.496 (0.0587 – 0.0589) ”3” 1.496 – 1.500 (0.0589 – 0.0591) Completely remove the plastigage. EM–67 ENGINE MECHANICAL 17. (a) (b) – CYLINDER BLOCK REMOVE PISTON AND CONNECTING ROD ASSEMBLIES Using a ridge reamer, remove all the carbon from the top of the cylinder. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT: A01166 A10458

Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order. 18. CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the crankshaft back and forth. Standard thrust clearance: 0.09 – 0.19 mm (0.0035 – 0.0075 in.) Maximum thrust clearance: 0.3 mm (0.012 in.) If the thrust clearance is greater than maximum, replace the thrust washer as a set. Thrust washer thickness: 2.430 – 2.480 mm (0.09567 – 0.09764 in.) 19. (a) REMOVE BEARING CAPS AND CHECK OIL CLEARANCE Uniformly loosen and remove the 10 bearing cap bolts in several passes in the sequence shown. A10459 (b) A10460 2001 PRIUS (RM778U) Using the 2 removed bearing cap bolts, remove the bearing cap and lower bearing by wiggling the bearing cap right and left. HINT: Keep the lower bearing inserted with the bearing cap. (c) Lift out the crankshaft. HINT: Keep the upper bearings and thrust washers together with the cylinder block. (d) Clean each main journal and bearing. EM–68 ENGINE MECHANICAL – CYLINDER BLOCK (e) Check each main journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearing. If necessary, grind or replace the crankshaft. (f) Place the crankshaft on the cylinder block. (g) (h) A10461 Lay a strip of plastigage acrose each journal. Install the bearing caps (See page EM–45). Torque: 1ST 22 N·m (220 kgf·cm, 16 ft·lbf) 2ND Turn 90 ° NOTICE: Do not turn the crankshaft. (i) Remove the bearing caps (See procedure (a) and (b) above). (j) Measure the plastigage at its widest point. Standard oil clearance: 0.010 – 0.023 mm (0.0004 – 0.0009 in.) Maximum oil clearance: 0.07 mm (0.0028 in.) If the oil clearance is greater then maximum, replace the bearings. If necessary, replace the crankshaft. A10462 No. 1 HINT: If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then selecting the bearing with the same number as the total. There are 4 sizes of standard bearings, marked ”1”, ”2”, ”3” and ”4” accordingly. No. 2 No. 3 No. 5 Total number No. 4 No. 5 No. 3 No. 1 Number Mark No. 4 No. 2 A10463 2001 PRIUS (RM778U) ” ”: Number mark Cylinder block (A) + Crankshaft (B) 0–2 3–5 6–8 9 –11 Use bearing ”1” ”2” ”3” ”4” EXAMPLE: Cylinder block ”4” (A) + Crankshaft ”3” (B) = Total number 7 (Use bearing ”3”) EM–69 ENGINE MECHANICAL – CYLINDER BLOCK Reference Item Mark mm (in.) Cylinder block main journal bore diameter (A) ”0” ”1” ”2” ”3” ”4” ”5” ”6” 50.000 – 50.003 (1.96850 – 1.96862) 50.003 – 50.005 (1.96862 – 1.96870) 50.005 – 50.007 (1.96870 – 1.96878) 50.007 – 50.010 (1.96878 – 1.96889) 50.010 – 50.012 (1.96889 – 1.96897) 50.012 – 50.014 (1.96897 – 1.96905) 50.014 – 50.016 (1.96905 – 1.96913) Crankshaft main journal diameter (B) ”0” ”1” ”2” ”3” ”4” ”5” 46.000 – 46.002 (1.81102 – 1.81110) 46.002 – 46.004 (1.81110 – 1.81118) 46.004 – 46.006 (1.81118 – 1.81126) 46.006 – 46.008 (1.81126 – 1.81133) 46.008 – 46.010 (1.81133 – 1.81141) 46.010 – 46.012 (1.81141 – 1.81149) Standard bearing center wall thickness ”1” ”2” ”3” ”4” 1.992 – 1.995 (0.07843 – 0.07854) 1.995 – 1.998 (0.07854 – 0.07866) 1.998 – 2.001 (0.07866 – 0.07878) 2.001 – 2.004 (0.07878 – 0.07890) (k) 20. (a) (b) Completely remove the Plastigage. REMOVE CRANKSHAFT Lift out the crankshaft. Remove the 5 upper main bearings and 2 thrust washers from the cylinder block. HINT: Arrange the main bearings and thrust washers in the correct order. 21. CHECK FIT BETWEEN PISTON AND PISTON PIN Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set. A12947 22. (a) REMOVE PISTON RINGS Using a piston ring expander, remove the 2 compression rings. Remove the oil ring by hand. (b) HINT: Arrange the piston rings in the correct order only. A12948 2001 PRIUS (RM778U) EM–70 ENGINE MECHANICAL SST SST SST A12963 2001 PRIUS (RM778U) – CYLINDER BLOCK 23. DISCONNECT CONNECTING ROD FROM PISTON Using SST, press out the piston pin from the piston. Remove the piston. SST 09221–25026 (09221–00021, 09221–00030, 09221–00190, 09221–00141, 09221–00150) HINT:
The piston and pin are a matched set.
Arrange the pistons, pins, rings, connecting rods and bearings in correct order. EM–71 ENGINE MECHANICAL – CYLINDER BLOCK EM17D–03 INSPECTION A01165 1. REMOVE GASKET MATERIAL Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. 2. CLEAN CYLINDER BLOCK Using a soft brush and solvent, thoroughly clean the cylinder block. NOTICE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block, so always wash the cylinder block at a temperature of 45°C (133°F) or less. 3. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR FLATNESS Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage. Maximum warpage: 0.05 mm (0.0020 in.) If warpage is greater than maximum, replace the cylinder block. A01169 4. INSPECT CYLINDER BORE DIAMETER Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block. A01167 2001 PRIUS (RM778U) EM–72 ENGINE MECHANICAL – CYLINDER BLOCK 5. INSPECT CYLINDER BORE DIAMETER Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions. Standard diameter: 75.000 – 75.013 mm (2.95275 – 2.95326 in.) Maximum diameter: 75.013 mm (2.95326 in.) If the diameter is greater than maximum, replace the cylinder block. 1 Front 2 1 Thrust Direction 2 Axial Direction A 10 mm (0.39 in.) B A01168 EM2548 C 10 mm (0.39 in.)A01467 6. REMOVE CYLINDER RIDGE If the wear is less than 0.2 mm (0.008 in,), using a ridge reamer, grind the top of the cylinder. A01166 7. INSPECT 12 POINTED HEAD BEARING CAP SUB– ASSEMBLY BOLTS Using vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 7.3 – 7.5 mm (0.287 – 0.295 in.) Minimum diameter: 7.3 mm (0.287 in.) If the diameter is less than minimum, replace the bolt. A01194 8. (a) A12949 2001 PRIUS (RM778U) CLEAN PISTON Using a gasket scraper, remove the carbon from the piston top. EM–73 ENGINE MECHANICAL (b) – CYLINDER BLOCK Using a groove cleaning tool or broken ring, clean the piston ring grooves. A12950 (c) Using solvent and a brush, thoroughly clean the piston. NOTICE: Do not use a wire brush. A12951 9. (a) 27 mm A12952 INSPECT PISTON OIL CLEARANCE Using a micrometer, while placing the piston up side down, take measurement at the position of 27 mm (1.06 in.). Piston diameter: 74.930 – 74.940 mm (2.94999 – 2.95039 in.) (b) Measure the cylinder bore diameter in the thrust directions. (See procedure in step 5) (c) Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.045 – 0.068 mm (0.00177 – 0.00268 in.) Maximum oil clearance: 0.095 mm (0.0037 in.) If the oil clearance is greater than maximum, replace all the 4 pistons. If necessary, replace the cylinder block. 10. INSPECT PISTON RING END GAP Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove. Ring groove clearance: 0.030 – 0.070 mm (0.0012 – 0.0028 in.) If the clearance is not as specified, replace the piston. A12953 2001 PRIUS (RM778U) EM–74 ENGINE MECHANICAL 11. (a) (b) (c) 110 mm A12954 – CYLINDER BLOCK INSPECT PISTON RING END GAP Insert the piston ring into the cylinder bore. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block. Using a feeler gauge, measure the end gap. Standard end gap: No. 1 0.22 – 0.32 mm (0.0087 – 0.0126 in.) No. 2 0.32 – 0.47 mm (0.0126 – 0.0185 in.) Oil (Side rail) 0.15 – 0.45 mm (0.0059 – 0.0177 in.) Maximum end gap: No. 1 0.88 mm (0.0346 in.) No. 2 1.03 mm (0.0406 in.) Oil 0.92 mm (0.0362 in.) If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, replace the cylinder block. EM7639 12. INSPECT CONNECTING ROD ALIGNMENT Using a rod aligner and feeler gauge, check the connecting rod alignment.
Check for out–of–alignment Maximum out–of alignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If out–of alignment is greater than maximum, replace the connecting rod assembly. Z00064
Check for twist Maximum twist: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If twist is greater than maximum, replace the connecting rod assembly. Z00065 13. (a) A01185 2001 PRIUS (RM778U) INSPECT PISTON PIN OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 18.010 – 18.019 mm (0.7091 – 0.7094 in.) EM–75 ENGINE MECHANICAL – CYLINDER BLOCK (b) EM0227 Using a micrometer, measure the piston pin diameter. Piston pin diameter: 17.988 – 18.007 mm (0.7086 – 0.7089 in.) (c) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.009 – 0.015 mm (0.0003 – 0.0006 in.) Maximum oil clearance: 0.05 mm (0.0020 in.) If the oil clearance is greater than maximum, replace the connecting rod. If necessary, replace the piston and piston pin as a set. 14. INSPECT CONNECTING ROD BOLTS Using a vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 6.6 – 6.7 mm (0.260 – 0.264 in.) Minimum diameter: 6.4 mm (0.252 in.) If the diameter is less than minimum, replace the bolt. A01470 15. (a) (b) INSPECT CRANKSHAFT FOR CIRCLE RUNOUT Place the crankshaft on V–blocks. Using a dial indicator, measure the circle runout, as shown in the illustration. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than maximum, replace the crankshaft. A11241 2001 PRIUS (RM778U) EM–76 ENGINE MECHANICAL 16. (a) – CYLINDER BLOCK INSPECT MAIN JOURNALS AND CRANK PINS Using a micrometer, measure the diameter of each main journal and crank pin. Main journal diameter: 45.988 – 46.000 mm (1.81054 – 1.81102 in.) Crank pin diameter: 39.992 – 40.000 mm (1.5745 – 1.5748 in.) If the diameter is not as specified, check the oil clearance. (See page EM–64) If necessary, replace the crankshaft. (b) Check each main journal and crank pin for taper and out– of–round as shown. Maximum taper and out–of–round: 0.02 mm (0.0008 in.) If the taper and out–of round is greater than maximum, replace the crankshaft. A11242 2001 PRIUS (RM778U) EM–78 ENGINE MECHANICAL – CYLINDER BLOCK EM1J4–02 REASSEMBLY HINT:


1. (a) (b) (Cavity) (c) (d) (Protrusion) Front Mark Thoroughly clean all parts to be assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. Replace all gaskets, O–rings and oil seals with new parts. ASSEMBLE PISTON AND CONNECTING ROD Gradually heat the piston side of connecting rod to 80 – 90°C (176 – 194°F). Coat the piston pin and pin holes of the piston with engine oil. Align the cavity on the piston with the protrusion on the connecting rod. Using SST, press in the piston pin. SST 09221–25026 (09221–00021, 09221–00030, 09221–00190, 09221–00141, 09221–00150) SST SST SST A12957 No. 2 2. (a) (b) INSTALL PISTON RINGS Install the oil ring expander and 2 side rails by hand. Using a piston ring expander, install the 2 compression rings. A12958 No. 1 Compression Oil Ring (Rail) Front Oil Ring (Expander) No. 2 Compression 2001 PRIUS (RM778U) A12959 (c) Position the piston rings so that the ring ends are as shown. NOTICE: Do not align the ring ends. EM–79 ENGINE MECHANICAL 3. A01190 A B C D A10470 9 5 1 3 7 10 6 2 4 8 Supply parts: INSTALL MAIN BEARINGS Manufacture parts: INSTALL MAIN BEARINGS HINT: Upper bearings have an oil groove and oil holes; Lower bearings do not. Measure the clearance on both sides of the bearing and install it so that the difference between measured values will be within the specified bellow. Specified clearance: A – B = 0.8 mm (0.032 in.) C – D = 0.4 mm (0.016 in.) 5. PLACE CRANKSHAFT ON CYLINDER BLOCK 6. INSTALL BEARING CAPS (a) Install the 5 bearing caps. HINT: Each bearing cap has a number and front mark. (b) Apply a light coat of engine oil on the threads and under the head of the bearing cap bolts. A10459 2001 PRIUS (RM778U) CYLINDER BLOCK HINT: Upper bearings have an oil groove and oil holes; Lower bearings do not. (a) Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings. NOTICE: Install the bearing with the oil hole in the cylinder block. (b) Align the bearing claw with the claw grove of the main bearing cap, and push in the 5 lower bearings. 4. Cap Side: Block Side: – EM–80 ENGINE MECHANICAL (c) (d) 7. – CYLINDER BLOCK Install and uniformly tighten the 10 bolts of the bearing cap is several passes, in the sequence shown. Torque: 1ST 22 N·m (220 kgf·cm, 16 ft·lbf) 2ND Turn 90 ° Check that the crankshaft turns smoothly. CHECK CRANKSHAFT THRUST CLEARANCE (See page EM–64) 8. A01205 INSTALL PISTON AND CONNECTING ROD ASSEMBLES Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. 9. PLACE CONNECTING ROD CAP ON CONNECTING ROD (a) Match the numbered connecting rod cap with the connecting rod. (b) Align the pin dowels of the connecting rod cap with the pins of the connecting rod, and install the connecting rod. (c) Check that the protrusion of the connecting rod cap is facing in the correct direction. 10. INSTALL CONNECTING ROD CAP BOLTS HINT:
The connecting rod cap bolts are tightened in 2 progressive steps (steps (b) and (d)).
If any of the connecting rod cap bolts is broken or deformed, replace it. (a) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. (b) A10456 2001 PRIUS (RM778U) Install and alternately tighten the 2 connecting rod cap bolts in several passes. Torque: 1ST 15 N·m (150 kgf·cm, 11 ft·lbf) 2ND Turn 90 ° If any of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts. 11. CHECK CONNECTING ROD THRUST CLEARANCE (See page EM–64) EM–81 ENGINE MECHANICAL 12. (a) (b) Seal Width 2 – 3 mm A10464 15 14 2 5 4 3 A B 6 7 8 12 B 1 9 C 11 10 A11271 2001 PRIUS (RM778U) CYLINDER BLOCK INSTALL OIL PAN NO. 1 Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the oil pan No. 1 and cylinder block.
Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
Thoroughly clean all components to remove all the loose material.
Using a non–residue solvent, clean both sealing surfaces. Apply seal packing to the oil pan No. 1 as shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent
Install a nozzle that has been cut to a 2 – 3 mm (0.08 – 0.12 in.) opening. HINT: Avoid applying an excessive amount to the surface.
Parts must be assembled within 3 minutes of application. Otherwise the material must be remove d and reapplied.
Immediately remove nozzle from the tube and reinstall cap. (c) Install new O–rings to the cylinder block. (d) Using a plastic–faced hammer, lightly tap the oil pan No. 1 to ensure a proper fit. (e) 13 – Install and uniformly tighten the 13 bolts, in several passes, in the sequence shown. Torque: 24 N·m (245 kgf·cm, 18 ft·lbf) HINT: Each bolt length in indicated in the illustration. A: 49 mm (1.929 in.) B: 88 mm (3.465 in.) C: 144 mm (5.669 in.) 13. INSTALL REAR CRANKSHAFT OIL SEAL (See page EM–77) HINT: Wipe seal packing away from the contact surface of the cylinder block assembly and oil seal. EM–82 ENGINE MECHANICAL A14342 A10465 16. 17. 2001 PRIUS (RM778U) Apply seal packing to the oil pan as shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent
Install a nozzle that has been cut to a 2.5 – 3.5 mm (0.098 – 0.138 in.) opening. HINT: Avoid applying an excessive amount to the surface.
Parts must be assembled within 3 minutes of application. Otherwise the material must be remove d and reapplied.
Immediately remove nozzle from the tube and reinstall cap. (c) A11269 CYLINDER BLOCK 14. INSTALL OIL STRAINER Install a new gasket, and oil strainer with the bolt and 2 nuts. Torque: 11 N·m (112 kgf·cm, 8 ft·lbf) 15. INSTALL OIL PAN (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the main bearing cap and oil pan.
Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
Thoroughly clean all components to remove all the loose material.
Using a non–residue solvent, clean both sealing surfaces. NOTICE: Do not use a solvent which will affect the painted surfaces. (b) Seal Width 2.5 – 3.5 mm – Install the oil pan with the 9 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes. Torque: 9.0 N·m (92 kgf·cm, 80 in.·lbf) INSTALL OIL FILTER UNION Torque: 30 N·m (306 kgf·cm, 21 ft·lbf) INSTALL OIL FILTER (See page LU–3) EM–83 ENGINE MECHANICAL 18. (a) Adhesive (b) P12477 23. 24. 25. 26. 2001 PRIUS (RM778U) CYLINDER BLOCK INSTALL ENGINE COOLANT DRAIN UNION Apply adhesive to 2 or 3 threads. Adhesive: Part No. 08833–00080, THREE BOND 1344, LOCTITE 242 or equivalent Install the drain union. Torque: 35 N·m (350 kgf·cm, 25 ft·lbf) HINT: After applying the specified torque, rotate the drain union clockwise until its drain port is facing downward. 19. INSTALL KNOCK SENSOR Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) 20. INSTALL OIL PRESSURE SWITCH (See page LU–1) 21. INSTALL THERMOSTAT (See page CO–12) 22. A10451 – INSTALL WATER BYPASS PIPE Torque: 9.0 N·m (92 kgf·cm, 80 in.·lbf) INSTALL ENGINE WIRE INSTALL CYLINDER HEAD (See page EM–45) INSTALL TIMING SPROCKETS AND TIMING CHAIN (See page EM–21) REMOVE ENGINE STAND EC–3 EMISSION CONTROL – PARTS LAYOUT AND SCHEMATIC DRAWING EC0HT–01 DRAWING VSV for EVAP Charcoal Canister Fuel Tank Refer to next page Air Cleaner Throttle Valve Heated Oxygen Sensor (Bank 1 Sensor 1) VSV for HCAC Heated Oxygen Sensor (Bank 1 Sensor 2) Check Valve Pressure Sensor for HCAC Actuator for HCAC B11797 2001 PRIUS (RM778U) EC–4 EMISSION CONTROL – PARTS LAYOUT AND SCHEMATIC DRAWING Air Cleaner Throttle Valve VSV for EVAP Purge Line VSV for Purge Flow Switching Valve Charcoal Canister Filler Pipe EVAP Line Fresh Air Valve Trap Filter Vapor Pressure Sensor Canister Closed Valve Fuel Tank B11798 2001 PRIUS (RM778U) EC–7 EMISSION CONTROL – EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM EC0HV–01 INSPECTION 1. REMOVE EXHAUST TAIL PIPE AND HEATED INSULATOR (See page EM–84) 2. INSPECT LINES AND CONNECTORS Visually check for loose connections, sharp bends or damage. 3. INSPECT FUEL TANK FILLER PIPE Visually check for deformation, cracks or fuel leakage. 4. INSPECT FUEL TANK CAP Visually check if the cap and/or gasket are deformed or damaged. If necessary, repair or replace the cap. Gasket B04812 5. (a) Vacuum Gauge (b) INSPECT EVAP SYSTEM LINE Warm up the engine and stop the engine. Allow the engine to warm up to normal operating temperature. Install a vacuum gauge (EVAP control system test equipment vacuum gauge) to the EVAP service port on the purge line. B06544 TOYOTA Hand–held Tester (c) TOYOTA hand–held tester: Forced driving of the VSV for the EVAP. (1) Connect a TOYOTA hand–held tester to the DLC3. (2) Start the engine. (3) Push the TOYOTA hand–held tester main switch ON. (4) Use the ACTIVE TEST mode on the TOYOTA hand–held tester to operate the VSV for the EVAP. (d) If you have no TOYOTA hand–held tester: Forced driving of the VSV for the EVAP. (1) Disconnect the VSV connector for the EVAP. (2) Connect the positive (+) and negative (–) leads from the battery to the VSV terminals for the EVAP. (3) Start the engine. F12396 B11799 2001 PRIUS (RM778U) EC–8 EMISSION CONTROL (e) B06545 – EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM Check the vacuum at idle. Vacuum: Maintain at 0.368 – 19.713 in. Hg (5 – 268 in.Aq) for over 5 seconds HINT: If the vacuum does not change, you can conclude that the hose connecting the VSV to the service port has come loose or is blocked, or the VSV is malfunctioning. (f) If you have TOYOTA hand–held tester: Conclude forced driving of the VSV for the EVAP. (1) Stop the engine. (2) Disconnect the TOYOTA hand–held tester from the DLC3. (g) If you have no TOYOTA hand–held tester: Conclude forced driving of the VSV for the EVAP. (1) Stop the engine. (2) Disconnect the positive (+) and negative (–) leads from the battery, and from the VSV terminals for the EVAP. (3) Connect the VSV connector for the EVAP. (h) Disconnect the vacuum gauge from the EVAP service port on the purge line. (i) Connect a pressure gauge to the EVAP service port on the purge line. (j) Check the pressure. (1) Close off the air drain hose at the marked position of the canister with a hose clipper or similar instrument. B11800 (2) Add the pressure (13.5 – 15.5 in.Aq) from the EVAP service port. Pressure: 2 minutes after the pressure is added, the gauge should be over 7.7 – 8.8 in.Aq. Pressure Gauge Pressure B06546 2001 PRIUS (RM778U) HINT: If you can’t add pressure, you can conclude that the hose connecting the VSV–canister–fuel tank has slipped off or the VSV is open. EC–9 EMISSION CONTROL TOYOTA Hand–held Tester 6. (a) DLC3 F12396 (b) CCV ECM – EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM CHECK AIRTIGHTNESS IN FUEL TANK AND FILLER PIPE TOYOTA hand–held tester: Forced driving of the VSV for the canister closed valve (CCV). (1) Connect a TOYOTA hand–held tester to the DLC3. (2) Turn the ignition switch ON. (3) Push the TOYOTA hand–held tester mode on the TOYOTA hand–held tester to operate the VSV for the canister closed valve (CCV). If you have no TOYOTA hand–held tester: Forced driving of the canister closed valve (CCV). (1) Remove the connector cover from the ECM. (2) Turn the ignition switch ON. (3) Connect the between terminal CCV of the ECM connector and body ground. B12247 (c) Add the pressure from the EVAP service port to 1.6 kPa (16.3 kgf/cm2, 0.232 psi). (d) Check that the pressure can be held for 30 seconds. (e) Visually check the fuel tank and filler pipes. (f) Check each connection of hoses and pipes. If there is abnormality, replace the fuel tank and filler pipe. B06545 7. (a) B12239 2001 PRIUS (RM778U) CHECK AIR INLET LINE Disconnect the air inlet line hose from the fresh air valve. EC–10 EMISSION CONTROL (b) (c) – EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM Disconnect the air inlet hose from the air cleaner case. Blow air into the air inlet line hose. B11801 (d) Check that the air flows from the air inlet line hose. (e) Visually check the air inlet line hoses and pipes. (f) Check each connection of hoses and pipes. If there is abnormality, replace the air inlet line hose and pipe. B12240 8. (a) (b) (c) (d) REMOVE CHARCOAL CANISTER ASSEMBLY Remove the fuel tank (See page SF–17) Disconnect the 3 hoses from the charcoal canister. Remove the 2 bolts and charcoal canister from the fuel tank. Remove the 2 bolts and VSV for purge flow switching from the charcoal canister. B11803 9. (a) INSPECT CHARCOAL CANISTER Visually check the charcoal canister for cracks or damage. (b) While holding port C closed, using low pressure compressed air (4.9 kPa (50 gf/cm2, 0.71 psi), blow into port A and check that air flows without resistance from the port B. B11804 Port C Port A Port B B11805 2001 PRIUS (RM778U) EC–11 EMISSION CONTROL – EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM Using low pressure compressed air (4.9 kPa (50 gf/cm2, 0.71 psi), blow into port A and check that air flows without resistance from the other ports. If a problem is found, replace the charcoal canister. 10. REINSTALL CHARCOAL CANISTER ASSEMBLY (c) Port C Port A Port B B11806 11. (a) (b) (c) (d) (e) B11807 REMOVE TRAP FILTER AND FRESH AIR VALVE Remove the fuel tank (See page SF–17). Disconnect the air inlet hoses from the VSV for canister closed valve. Disconnect the connector from the fresh air valve. Remove the bolt and disconnect the air opening valve from the VSV for canister closed valve. Remove the 2 bolts and VSV for canister closed valve with the trap filter. (f) Remove the 2 bolts and trap filter from the VSV for canister closed valve. 12. (a) INSPECT TRAP FILTER Visually check the trap filter for cracks or damage. B11808 B11809 (b) Inspect the trap filter operation. Blow air into port A, check that the air flows from port B. If a problem is found, replace the trap filter. Port A Port B B11810 2001 PRIUS (RM778U) EC–12 EMISSION CONTROL 13. (a) (b) EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM INSPECT FRESH AIR VALVE Visually check the fresh air valve for cracks or damage. Inspect the fresh air valve operation. Blow air into port A, check that the air flows from port B and C. If a problem is found, replace the fresh air valve. 14. REINSTALL TRAP FILTER AND FRESH AIR VALVE Port C Port A Port B B11811 2001 PRIUS (RM778U) – EMISSION CONTROL – THREE–WAY CATALYTIC CONVERTER (TWC) SYSTEM EC–13 THREE–WAY CATALYTIC CONVERTER (TWC) SYSTEM EC0HW–01 INSPECTION 1. CHECK TWC FOR DENTS OR DAMAGE If any port of the heat insulator is damaged to the extent that it contacts the three–way catalytic converter, repair or replace it. 2. CHECK EXHAUST PIPE CONNECTIONS FOR LOOSENESS OR DAMAGE 3. CHECK EXHAUST PIPE CLAMPS FOR WEAKNESS, CRACKS OR DAMAGE 4. CHECK HEAT INSULATOR FOR DAMAGE 5. CHECK FOR ADEQUATE CLEARANCE BETWEEN EXHAUST SYSTEM AND HEAT INSULATOR ON THE BODY TOYOTA Hand–held Tester 6. (a) (b) DLC3 F12396 (c) INSPECT HC ABSORBER AND CATALYST SYSTEM Warm up the engine. TOYOTA hand–held tester: Forced driving of the VSV for the HC absorber and catalyst system. (1) Connect a TOYOTA hand–held tester to the DLC3. (2) Start the engine. (3) Push the TOYOTA hand–held tester mode on the TOYOTA hand–held tester to operate the VSV for the HC absorber and catalyst system. If you have no TOYOTA hand–held tester: Forced driving of the VSV for the TOYOTA HC absorption catalyst system. (1) Disconnect the VSV connector for the TOYOTA HC absorption catalyst system. (2) Connect the positive (+) and negative (–) leads from the battery to the VSV. (3) Start the engine. B11812 (d) Check that the rod of the actuator is pulled and the valve is operating. If not in operation, check the vacuum hose line or VSV, actuator. B11813 2001 PRIUS (RM778U) Author: Date: 1213 EC–14 EMISSION CONTROL – THREE–WAY CATALYTIC CONVERTER (TWC) SYSTEM 7. (a) (b) (c) B11814 INSPECT ACTUATOR Remove the front exhaust pipe. Remove the actuator from the front exhaust pipe. Connect the MITYVAC (hand–held vacuum pump) to the actuator port. (d) Apply vacuum (more than 33.3 kPa, 250 mmHg, 9.83 in.Hg), make sure that the rod is retracted. If the not, replace the actuator. (e) Disconnect the MITYVAC (hand–held vacuum pump) from the actuator port. 8. INSPECT VALVE OPERATION (a) Turn the valve stay by hand and ensure that it can turn. If the not, replace the front exhaust pipe. (b) Install the actuator to the front exhaust pipe. (c) Install the front exhaust pipe. B11831 2001 PRIUS (RM778U) Author: Date: 1214 SF–1 SFI – SFI SYSTEM SFI SYSTEM SF1KN–01 PRECAUTION 1. BEFORE WORKING ON THE FUEL SYSTEM , DISCONNECT THE NEGATIVE (–) TERMINAL CABLE FROM THE BATTERY AND HV BATTERY SERVICE PLUG HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (–) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (–) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON THE FUEL SYSTEM 3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS 4. MAINTENANCE PRECAUTIONS (a) In event of engine misfire, these precautions should be taken. (1) Check proper connection to battery terminals, etc. (2) After repair work, check that the ignition coil terminals and all other ignition system lines are reconnected securely. (3) When cleaning the engine compartment, be especially careful to protect the electrical system from water. (b) Precautions when handling oxygen sensor. (1) Do not allow oxygen sensor to drop or hit against an object. (2) Do not allow the sensor to come into contact with water. If vehicle is Equipped with Mobile Radio System (HAM, CB, etc.) If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section. 5. AIR INDUCTION SYSTEM (a) Separation of the engine oil dipstick, oil filler cap, PCV hose, etc. may cause the engine to run out of turn. (b) Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will allow air suction and cause the engine to run out of turn. 6. ELECTRONIC CONTROL SYSTEM (a) Before removing SFI wiring connectors, terminals, etc., first disconnect the power by either turning the ignition switch to LOCK or disconnecting the negative (–) terminal cable from the battery. HINT: Always check the diagnostic trouble code before disconnecting the negative (–) terminal cable from the battery. 2001 PRIUS (RM778U) Author: Date: 1215 SF–2 SFI (b) (c) (d) (e) (f) (g) (h) – SFI SYSTEM When installing the battery, be especially careful not to incorrectly connect the positive (+) and negative (–) cables. Do not permit parts to receive a severe impact during removal or installation. Handle all SFI parts carefully, especially the ECM. Be careful during troubleshooting as there are numerous transistor circuit, and even slight terminal contact can cause further troubles. Do not open the ECM cover. When inspecting during rainy weather, take care to prevent entry of water. Also, when washing the engine compartment, prevent water from getting on the SFI parts and wiring connectors. Parts should be replaced as an assembly. Care should be taken when pulling out and inserting wiring connectors. (1) Release the lock and pull out the connector, pulling on the connectors. (2) Fully insert the connector and check that it is locked. (i) Use SST for inspection or test of the injector or its wiring connector. SST 09842–30080 7. (a) FUEL SYSTEM When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures. (1) Disconnect the fuel pump connector. (2) Start the engine. After the engine has stopped on its own, turn the ignition switch to LOCK. (3) Disconnect the fuel tube from the fuel tank. (4) Drain the fuel remained inside the fuel tube. SST B00417 Fuel Pump Connector B11832 (5) Prevent the disconnected fuel tube from damaging and mixing foreign objects by covering them with a vinyl bag. Vinyl Bag B00679 2001 PRIUS (RM778U) Author: Date: 1216 SF–3 SFI New O–ring CORRECT – SFI SYSTEM (b) Observe these precautions when removing and installing the injector. (1) Never reuse the O–ring. (2) When placing a new O–ring on the injector, take care not to damage it in any way. (3) Coat a new O–ring with spindle oil or gasoline before installing never use engine, gear or brake oil. (c) Install the injector to the delivery pipe and cylinder head, as shown in the illustration. Before in installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe or a cylinder head touches on O–ring of the injector. (d) Observe these precautions when disconnecting the fuel delivery pipe. The structure of the metallic connector is shown as left. (1) Remove the fuel pipe clamp. Delivery Pipe Injector WRONG B00061 Delivery Pipe O–ring Spacer Grommet B00062 O–Ring Nylon Tube Retainer Pipe Housing B11839 (2) Get the metallic connector of the fuel tube assembly, pull it out towards the rear and hold it as it is. (3) Assemble SST to the connection as shown. SST 09268–21010 SST B07690 (4) Turn SST, align the retainers inside the connector with SST chamfered parts and incert SST into the connector. Retainer (at 4 places) B11817 2001 PRIUS (RM778U) Author: Date: 1217 SF–4 SFI (5) (6) – SFI SYSTEM Hold SST as it at step 4, push the connector towards SST to put the retainers on SST champfered parts. Slide SST and the connector together towards the fuel tube assembly. B11818 (e) Observe these precautions when disconnecting the fuel tube connector (quick type). (1) Check if there is any dirt like mud on the pipe and around the connector before disconnecting them and clean the dirt away. A13909 (2) (3) (4) Be sure to disconnect with hands. When the connector and the pipe are stuck, pinch the retainer between the hands, push and pull the connector to free to disconnect and pull it out. Do not use any tool at this time. Inspect if there is any dirt or the likes on the seal surface of the disconnected pipe and clean it away. B11815 (5) Vinyl Bag Prevent the disconnected pipe and connector from damaging and mixing foreign objects by covering them with a vinyl bag. B00192 (f) Retainer Observe these precautions when connecting the fuel tube connector (quick type). (1) Do not reuse the retainer removed from the pipe. (2) Must use hands without using tools when to remove the retainer from the pipe. (3) Check if there is any damage or foreign objects on the connected part of the pipe. S05382 2001 PRIUS (RM778U) Author: Date: 1218 SF–5 SFI – (4) (5) SFI SYSTEM Match the axis of the connector with axis of the pipe, and push in the connector until retainer makes a ”click” sound. In case that the connections is tight, apply little amount of new engine oil on the tip of the pipe. After having finished the connection, check if the pipe and the connector are securely connected by pulling them. B11830 (g) A13909 TOYOTA Hand–Held Tester DLC3 F12396 (h) (6) Check if there is any fuel leakage. Observer these precautions when handling nylon tube. (1) Pay attention not to turn the connected part of the nylon tube and the quick connector with force when connecting them. (2) Pay attention not to kink the nylon tube. (3) Do not remove the nylon tube. (4) Must not close the piping with the nylon tube by bending it. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. (1) Connect the TOYOTA hand–held tester to the DLC3. (2) Turn the ignition switch ON and push TOYOTA hand–held tester main switch ON. (3) Select the active test mode on the TOYOTA hand– held tester. (4) Please refer to the TOYOTA hand–held tester operator’s manual for further details. (5) If you have no TOYOTA hand–held tester, connect the positive (+) and negative (–) leads from the battery to the fuel pump connector. (See page SF–6) (6) Check that there are no leaks from any part of the fuel system. (7) Turn the ignition switch to LOCK. (8) Disconnect the TOYOTA hand–held tester from the DLC3. 2001 PRIUS (RM778U) Author: Date: 1219 SF–6 SFI TOYOTA Hand–Held Tester – FUEL PUMP FUEL PUMP SF1KO–01 ON–VEHICLE INSPECTION 1. (a) (b) DLC3 F12396 3 CHECK FUEL PUMP OPERATION Connect the TOYOTA hand–held tester to the DLC3. Turn the ignition switch ON and TOYOTA hand–held tester main switch ON. NOTICE: Do not start the engine. (c) Select the active test mode on the TOYOTA hand–held tester. (d) Please refer to the TOYOTA hand–held tester operator’s manual for further details. (e) If you have no TOYOTA hand–held tester, connect the positive (+) lead from the battery to terminal 3 of the connecter, and the negative (–) lead to terminal 7. (f) Check that there is pressure in the fuel inlet pipe from the fuel line. 7 Battery B11794 B11816 HINT: If there is fuel pressure, you will hear the sound if fuel following. If there is no pressure, check these parts, Fusible link, Fuses, EFI Main relay, Fuel pump, ECM, and Witting connector. (g) Turn the ignition switch to LOCK. (h) Disconnect the TOYOTA hand–held tester from the DLC3. 2. (a) (b) Fuel Tube Connector (c) CHECK FUEL PRESSURE Check the battery positive voltage is above 12 V. Disconnect the negative (–) terminal cable from the battery. Purchase the new fuel tube and take out the fuel tube connector from its pipe. Part No.: 23901–21020 B09225 2001 PRIUS (RM778U) Author: Date: 1220 SF–7 SFI – FUEL PUMP (d) B11815 Disconnect the fuel tube (fuel tube connector) from the fuel pipe. CAUTION:
Perform disconnecting operations of the fuel tube connector (quick type) after observing the precautions.
As there is retained pressure in the fuel pipe line, prevent if from splashing inside the engine comportment. (e) SST (Hose) SST (Hose) SST SST (f) (g) Retainer Fuel pipe Install SST (pressure gauge) as shown in the illustration by using SST and fuel tube connector. SST 09268–41047 (95336–08070), 09268–45014 (09268–41200, 09268–41220, 09268–41250) Wipe off any splattered gasoline. Reconnect the negative (–) terminal cable to the battery. SST (Hose) Fuel Tube Connection B00194 3 7 Battery B11794 (h) Connect the TOYOTA hand–held tester to the DLC3. If you have no TOYOTA hand–held tester, connect the positive (+) lead from the battery to terminal 3 of the connecter, and the negative (–) lead to terminal 7. (i) Measure the fuel pressure. Fuel pressure: 304 – 343 kPa (3.1 – 3.5 kgf/cm2, 44 – 50 psi) If pressure is high, replace the fuel tank. If pressure is low, check the Fuel hoses and connections, Fuel pump. (j) Disconnect the TOYOTA hand–held tester from the DLC3. (k) Start the engine. (l) Measure the fuel pressure at idle. Fuel pressure: 304 – 343 kPa (3.1 – 3.5 kgf/cm2, 44 – 50 psi) (m) Stop the engine. (n) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. 2001 PRIUS (RM778U) Author: Date: 1221 SF–8 SFI A13909 Ohmmeter 3 7 – FUEL PUMP Fuel pressure: 147 kPa (1.5 kgf/cm2, 21 psi) or more If pressure is not as specified, check the fuel pump and/or injectors. (o) After checking fuel pressure, disconnect the negative (–) terminal cable from the battery and carefully, remove the SST and fuel tube connector to prevent gasoline from splashing. SST 09268–41047 (95336–08070), 09268–45014 (09268–41200, 09268–41220, 09268–41250) (p) Reconnect the fuel tube (fuel tube connector). CAUTION: Perform connecting operations of the fuel tube connector (quick type) after observing the precautions. (q) Reconnect the negative (–) terminal cable to the battery. (r) Check for fuel leakage. 3. REMOVE REAR SEAT CUSHION 4. REMOVE FLOOR SERVICE HOLE COVER 5. DISCONNECT FUEL PUMP & SENDER GAUGE CONNECTOR 6. INSPECT FUEL PUMP RESISTANCE Using an ohmmeter, measure the resistance between terminals 3 and 7. Resistance: 0.2 – 3.0 Ω at 20°C (68 °F) If the resistance is not as specified, replace the fuel tank. B11793 3 7 Battery B11794 7. INSPECT FUEL PUMP OPERATION Connect the positive (+) lead from the battery to terminal 3 of the connector and the negative (–) terminal 7. Check that the pump operates. NOTICE:
These tests must be done quickly (within 10 seconds) to prevent the coil burning out.
Keep fuel pump as far away from the battery as possible.
Always do the switching at the battery side. If operation is not as specified, replace the lead wire or fuel tank. 8. RECONNECT FUEL PUMP & SENDER GAUGE CONNECTOR 9. REINSTALL FLOOR SERVICE HOLE COVER 10. REINSTALL REAR SEAT CUSHION 2001 PRIUS (RM778U) Author: Date: 1222 SF–12 SFI – INJECTOR SF09K–11 INSPECTION SST (Hose) Fuel Tube Connector SST (Union) 1. INSPECT INJECTOR INSPECTION CAUTION: Keep injector clear of sparks during the test. SST (Clamp) Fuel Pipe (On vehicle) Injector B00066 (a) Fuel Tube Connector Purchase the new fuel tube and take out the fuel tube connector from its pipe. Part No. 23901–22010 S05359 (b) Connect SST (hose) and fuel tube connector to the fuel pipe. SST 09268–41047 CAUTION: Perform connecting operations of the fuel tube connector (quick type) after observing the precautions. SST (Hose) Fuel Tube Connector Fuel Pipe B00067 SST (Hose) (c) (d) SST (Union) O–Ring SST (Clamp) Vinyl Tube Install the grommet and O–ring to the injector. Connect SST (union and hose) to the injector, and hold the injector to prevent gasoline from splashing out. SST 09268–41047 Put the injector into a graduated cylinder. (e) HINT: Install a suitable vinyl tube onto the injector to prevent gasoline from splashing out. B00068 TOYOTA Hand–Held Tester DLC3 F12396 2001 PRIUS (RM778U) (f) (g) Connect the TOYOTA hand–held tester to the DLC3. Turn the ignition switch ON and TOYOTA hand–held tester main switch ON. NOTICE: Do not start the engine. (h) Select the active test mode on the TOYOTA hand–held tester. (i) Please refer to the TOYOTA hand–held tester operator’s manual for further details. SF–13 SFI (j) – INJECTOR If you have no TOYOTA hand–held tester, connect the positive (+) and negative (–) leads from the battery to the fuel pump connector (See page SF–9). (k) SST (Wire) Battery B00416 Connect SST (wire) to the injector and battery for 15 seconds, and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. SST 09842–30080 Volume: 36 – 46 cm3 (2.1 – 2.8 cu in.) per 15 sec. Difference between each injector: 10 cm3 (0.6 cu in.) or less If the injection volume is not as specified, replace the injector. 2. (a) B00069 2001 PRIUS (RM778U) INSPECT LEAKAGE In the condition above, disconnect the test probes of SST (wire) from the battery and check the fuel leakage from the injector. SST 09842–30080 Fuel drop: 1 drop or less per 12 minutes (b) Turn the ignition switch to LOCK. (c) Disconnect the negative (–) terminal cable from the battery. (d) Remove the SST and fuel tube connector. SST 09268–41047 CAUTION:
Perform disconnecting operations of the fuel tube connector (quick type) after observing the precautions.
As there is retained pressure in the fuel pipe line, prevent it from splashing inside the engine compartment. (e) Disconnect the TOYOTA hand–held tester from the DLC3. SF–14 SFI – INJECTOR SF1KQ–01 INSTALLATION New Grommet 1. (a) (b) INSTALL INJECTORS AND DELIVERY PIPES Install the grommet to each injector. Apply a light coat of spindle oil or gasoline to new O–ring and install them to each injector. (c) Apply a light coat of spindle oil or gasoline on the place where a delivery pipe touches on O–ring. While turning the injector clockwise and counterclockwise, push it to the delivery pipes. Install the 4 injectors. Position the injector connector outward. Place the 2 spacers in position on the cylinder head. Place the delivery pipe and fuel pipe together with the 4 injectors in position on the cylinder head. New O–Ring B00201 Turn Connector (d) Push (e) (f) (g) B00202 (h) (i) Temporarily install the 2 bolts holding the delivery pipe to the cylinder head. Temporarily install the bolt holding the fuel pipe to the cylinder head. B11777 (j) Check that the injectors rotate smoothly. HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of O–ring. Replace the O–ring. (k) Position the injector connector connector outward. Rotate Outward B11838 (l) (m) B11777 2001 PRIUS (RM778U) Tighten the 2 bolts holding the delivery pipe to the cylinder head. Torque: 19 N·m (194 kgf·cm, 14 ft·lbf) Tighten the bolt holding the fuel pipe to the cylinder head. Torque: 9.0 N·m (92 kgf·cm, 80 in.·lbf) SF–15 SFI – INJECTOR 2. CONNECT FUEL TUBE Connect the fuel tube (fuel tube connector) to the fuel pipe. CAUTION: Perform connecting operations of the connector (quick type) after observing the precautions. 3. INSTALL CYLINDER HEAD COVER (See page EM–21) B11830 2001 PRIUS (RM778U) SF–17 SFI – FUEL TANK AND LINE SF1KR–01 COMPONENTS 39 (398, 29) 39 (398, 29) Fuel Tank Assembly 39 (398, 29) Tail Pipe Parking Brake Cable Heated Oxygen Sensor (Bank 1 Sensor 2)
Gasket Front Exhaust Pipe 62 (632, 46) 45 (459, 33) Vacuum Hose for HCAC
Gasket N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part 2001 PRIUS (RM778U) B11453 SF–18 SFI – FUEL TANK AND LINE VSV for Purge Flow Switching Valve Vapor Pressure Sensor 39.2 (400, 29) 39.2 (400, 29) Charcoal Canister Fuel Tank Canister Closed Valve Trap Filter Fresh Air Valve N·m (kgf·cm, ft·lbf) : Specified torque 2001 PRIUS (RM778U) B11454 SF–24 SFI – THROTTLE BODY THROTTLE BODY SF1KS–01 ON–VEHICLE INSPECTION 1. (a) (b) TOYOTA Hand–Held Tester DLC3 F12396 Ohmmeter INSPECT SYSTEM OPERATION Disconnect the throttle control motor connector. Turn the ignition switch ON. (c) Inspect the throttle position sensor function. (1) Connect the TOYOTA hand–held tester to the DLC3. (2) When turning the throttle linkage to the full open position, check that the throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA shows the standard value. Throttle valve opening percentage: 60 % or more If operation is not as specified, check that the throttle position sensor, wiring and ECM. (d) Connect the throttle control motor connector. (e) Transit to the inspection mode and start the engine. (f) Allow the engine to warm up to normal operating temperature. (g) To check the charging rate of the HV battery, move the shift lever to D range and check that the engine stops. If it does not stop, the charging rate may be low. With the shift lever in P range, keep running the engine for a while. Then, shift lever to D range again and check that the engine stops. (h) Start the engine. (i) Turn the A/C switch ON and OFF, and check the idle speed. Idle speed (Transmission in neutral): 1,000 ± 50 rpm (A/C OFF) 1,200 ± 50 rpm (A/C ON) NOTICE: Perform inspection under condition without electrical load. (j) Stop the engine and disconnect TOYOTA hand–held tester from the DLC3. 2. (a) (b) INSPECT THROTTLE CONTROL MOTOR Disconnect the throttle control motor connector. Using an ohmmeter, measure the resistance between terminal M+ and M–. Resistance: 0.3 – 100 Ω at 20°C (68°F) If the resistance is not as specified, replace the throttle body. 1 (M–) 2 (M+) B11458 2001 PRIUS (RM778U) Author: Date: 1238 SF–25 SFI – THROTTLE BODY (c) 3. (a) (b) Ohmmeter E2 VC B11459 Reconnect the throttle control motor connector. INSPECT THROTTLE POSITION SENSOR Disconnect the throttle position sensor connector. Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 1.2 – 3.2 kΩ at 20°C (68°F) If the resistance is not as specified, replace the throttle position sensor. (See page SF–29) (c) Reconnect the throttle position sensor connector. 4. INSPECT ACCELERATOR PEDAL POSITION SENSOR (See page SF–59) 2001 PRIUS (RM778U) Author: Date: 1239 SF–26 SFI – THROTTLE BODY SF0NM–09 COMPONENTS Air Cleaner Assembly PCV Hose 20 (204, 15) Purge Line Hose 20 (204, 15) Throttle Body Assembly Trottle Control Motor Connector Trottle Position Sensor Connector
Gasket Water Bypass Hose N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part 2001 PRIUS (RM778U) B11460 SF–27 SFI – THROTTLE BODY Trottle Position Sensor Throttle Body 1.7 (17.5, 15 in.·lbf) N·m (kgf·cm, ft·lbf) : Specified torque 2001 PRIUS (RM778U) B11461 SF–29 SFI – THROTTLE BODY SF1KT–01 REPLACEMENT NOTICE:
To prevent deterioration, do not shock the throttle position sensor.
Mixing of the foreign objects may cause the gear locking, so thoroughly check that there is no stuck of any foreign objects and clean up if any. REPLACE THROTTLE POSITION SENSOR (a) Remove the 2 set screws and throttle position sensor. (b) Reinstall the throttle position sensor. (1) Check that the throttle valve is under the condition of the opener opening angle (about 3.5°). B11465 (2) (3) Install the sensor to the place where is at 15° rotated to the right from the specified installation position. Gradually turn sensor counterclockwise until it touches the throttle valve shaft and temporarily torque the 2 set screws. (3) (2) 15° B11466 (c) Turn 2001 PRIUS (RM778U) B11467 Adjust the throttle position sensor. (1) Connect the throttle position sensor connector. NOTICE: At this time, do not connect the throttle control motor connector. (2) Connect the TOYOTA hand–held tester to the DLC3. (3) Turn the ignition switch ON. NOTICE: After turning the ignition switch ON, do not depress the accelerator pedal. (4) While reading the value of the throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA, turn the throttle position sensor slowly to left and set the sensor at the center value of the standard value, and then torque the screws. Torque: 1.7 N·m (17.5 kgf·cm, 15 in.·lbf) Standard throttle valve opening percentage: 14.8 ± 0.8 % SF–30 SFI – THROTTLE BODY NOTICE: At the time of tightening the screw, as the sensor itself tends to turn causing to slanting, check that it is within the standard value after having finished the torque. (5) Fully close the throttle valve with a screwdriver and check that the value of the throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA stays with the standard value. Standard throttle valve opening percentage: 10 – 14 % If the throttle valve opening percentage is not as specified, repeat steps (4) through (5). (6) Paint the sensor set screws. (7) Turn the ignition switch OFF. (8) Disconnect the TOYOTA hand–held tester or from the DLC3. (9) Disconnect the throttle position sensor connector. 2001 PRIUS (RM778U) SF–42 SFI – VSV FOR CANISTER CLOSED VALVE (CCV) SF1KX–01 INSPECTION 1. 2. (a) (b) (c) B11807 (d) (e) REMOVE FUEL TANK (See page SF–17) REMOVE VSV Disconnect the air inlet hoses from the VSV for canister closed valve. Disconnect the connector from the VSV for canister closed valve. Remove the bolt and disconnect the air opening valve from the VSV for canister closed valve. Remove the 2 bolts and VSV for canister closed valve with the trap filter. Remove the 2 bolts and VSV for canister closed valve from the trap filter. B11808 Ohmmeter 3. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the terminals. Resistance: 25 – 30 Ω at 20 °C (68 °F) If there is no continuity, replace the VSV. Continuity B11746 Ohmmeter No Continuity B11747 5. (a) B A A Air B11748 2001 PRIUS (RM778U) 4. INSPECT VSV FOR GROUND Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is no continuity, replace the VSV. INSPECT VSV OPERATION Check that air flows from ports A to B. SF–43 SFI VSV FOR CANISTER CLOSED VALVE (CCV) (b) Apply battery positive voltage across the terminals. (c) Check that air does not flow from ports A to B. If operation is not as specified, replace the VSV. 6. REINSTALL VSV Battery B A Air B11749 2001 PRIUS (RM778U) – CO–2 COOLING – COOLANT CO04E–09 Engine Drain Plug Radiator Drain Plug B11768 2001 PRIUS (RM778U) REPLACEMENT 1. DRAIN ENGINE COOLANT (a) Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. (b) Loosen the radiator drain plug (on the right side of the radiator lower tank) and engine drain plug on the engine coolant drain union (on the right front of the cylinder block), and drain the coolant. (c) Close the drain plugs. Torque: 12.7 N·m (130 kgf·cm, 9 ft·lbf) for engine 2. FILL ENGINE COOLANT (a) Slowly fill the system with coolant.
Use of improper coolants may damage the engine cooling system.
Use ”Toyota Long Life Coolant” or equivalent and mix it with plain water according to the manufacture directions.
Use of the coolant which includes more than 50% [freezing protection down to –35°C (–31°F)] or 60% [freezing protection down to –50°C (–58°F)] of ethylene–glycol is recommended, but not more than 70%. NOTICE:
Do not use an alcohol type coolant or plain water alone.
The coolant should be mixed with plain water (preferably demineralized water or distilled water). Capacity: 4.9 litters (5.2 US qts, 4.3 lmp qts) (b) Install the radiator cap and start the engine. After repeatedly idling and racing the engine several times for approx. 2 minutes, stop the engine. (c) Remove the radiator cap and fill the radiator with engine coolant until it reaches the rim of the radiator filler. If the engine coolant level of the radiator drops when grasping the radiator inlet hose and outlet hose several times by hand, add more coolant. (d) Install the radiator cap. Activate inspection mode (See page IN–10). Warm it up until the radiator fan starts to turn with the engine speed at less than 2,500 rpm. NOTICE: Stop the engine immediately after the radiator fan starts to turn. (e) Stop the engine and cool it down. NOTICE: Cool down the engine until its temperature becomes below 50°C (122 °F). CO–3 COOLING (f) (g) (h) – COOLANT Remove the radiator cap and check the engine coolant level of the radiator. If it has dropped, repeat steps (d) to (g). Bleed air from water pump. Set the vehicle in the following conditions:
Ignition switch ON
Blower speed control dial to LO
Temperature control dial to MAX. HOT Operate the water pump in the following conditions:
The engine stopped
The blower switch ON
Temperature control dial at MAX. HOT HINT: Operate the water pump until a sound of the air–containing engine coolant can not be heard from the heater core. (i) When the engine coolant remains full, fill the radiator reservoir tank with engine coolant to the maximum level. 3. CHECK FOR COOLANT LEAKS 4. CHECK ENGINE COOLANT SPECIFIC GRAVITY IS CORRECT 2001 PRIUS (RM778U) CO–14 COOLING – RADIATOR AND CONDENSER MODULE CO143–01 ON–VEHICLE INSPECTION 1. REMOVE RADIATOR CAP CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. 2. INSPECT RADIATOR CAP NOTICE:
If the radiator cap has contaminations, always rinse it with water.
Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water.
When performing steps (a) and (b) below, keep the radiator cap tester at an angle of over 30°above the horizontal. (a) Radiator Cap Tester 30° or More Radiator Cap Z00570 2001 PRIUS (RM778U) Using a radiator cap tester, slowly pump the tester and check that air is coming from the vacuum valve. Pump speed: 1 push/(3 seconds or more) NOTICE: Push the pump at a constant speed. If air is not coming from the vacuum valve, replace the radiator cap. (b) Pump the tester and measure the relief valve opening pressure. Pump speed: 1 push within 1 seconds NOTICE: This pump speed is for the first pump only (in order to close the vacuum value). After this, the pump speed can be reduced. Standard opening pressure: 74 – 103 kPa (0.75 – 1.05 kgf·cm2, 10.7 – 14.9 psi) Minimum opening pressure: 79 kPa (0.8 kgf·cm2, 11.5 psi) HINT: Use the tester’s maximum reading as the opening pressure. If the opening pressure is less than minimum, replace the radiator cap. CO–15 COOLING 3. (a) Radiator Cap Tester B11773 2001 PRIUS (RM778U) – RADIATOR AND CONDENSER MODULE INSPECT COOLING SYSTEM FOR LEAKS Fill the radiator with coolant and attach a radiator cap tester. (b) Warm up the engine. (c) Pump it to 118 kPa (1.2 kgf·cm2, 17.1 psi), and check that the pressure drops. If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head. 4. REINSTALL RADIATOR CAP CO–17 COOLING – RADIATOR AND CONDENSER MODULE CO145–01 REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 500 ± 50 g (17.64 ± 1.76 oz.) 2. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant. 3. REMOVE ELECTRIC COOLING FAN ASSEMBLY (See Page CO–22) 4. REMOVE FRONT BUMPER (See Page BO–4) 5. REMOVE RADIATOR RESERVOIR HOSE 6. (a) I17955 DISCONNECT DISCHARGE AND LIQUID TUBE Remove the 2 bolts and disconnect discharge and liquid tube. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) NOTICE: Cap open the fittings immediately to keep moisture or dirt out of the system. HINT: At the time of installation, please refer to the following item. Lubricate 2 new O–rings with compressor oil and install them to the tubes. (b) Remove the bolt. (c) Disconnect the liquid tube and remove the bracket. 7. REMOVE RADIATOR UPPER SUPPORT Remove the 2 bolts and 2 radiator upper supports. I17954 2001 PRIUS (RM778U) CO–18 COOLING 8. (a) (b) (c) I17968 2001 PRIUS (RM778U) – RADIATOR AND CONDENSER MODULE REMOVE RADIATOR & CONDENSER MODULE Push the radiator & condenser module toward engine. Pull up the radiator until the lower radiator support is removed. Pull it downward to remove it. CO–22 COOLING – ELECTRIC COOLING FAN CO149–01 REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 500 ± 50 g (17.64 ± 1.76 oz.) 2. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all coolant. 3. (a) (b) REMOVE BRACKETS Remove the water hose from fan shroud. Remove the 5 bolts and 2 brackets. 4. (a) REMOVE SUCTION AND DISCHARGE HOSES Remove the 2 bolts and disconnect the both hoses. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) I17963 I17964 2001 PRIUS (RM778U) HINT: At the time of installation, please refer to the following item. Lubricate 2 new O–rings with compressor oil and install them to the tubes. (b) Loosen the 2 nuts and remove the both hoses. Torque: Suction hose 32 N·m (330 kgf·cm, 24 ft·lbf) Discharge hose 22 N·m (225 kgf·cm, 16 ft·lbf) HINT: At the time of installation, please refer to the following item. Lubricate 2 new O–rings with compressor oil and install them to the tubes. CO–23 COOLING 5. – ELECTRIC COOLING FAN (b) DISCONNECT RADIATOR HOSES FROM RADIATOR AND CONDENSER MODULE Using pliers, grip the claw of the hose clip and slide the clip along the hose. Disconnect the radiator hoses. 6. (a) (b) REMOVE ELECTRIC COOLING FAN ASSEMBLY Disconnect the 2 connectors. Remove the 2 bolts. (c) Pull up the electric cooling fan assembly until the it is removed from the radiator and condenser module. Pull it downward to remove it. (a) I17965 I17967 (d) I17956 2001 PRIUS (RM778U) CO–27 COOLING – COOLING FAN RELAY COOLING FAN RELAY CO14D–01 INSPECTION 1. (a) (b) No. 1 Cooling Fan Relay INSPECT NO. 1 COOLING FAN RELAY Remove the relay box cover. Remove the No. 1 cooling fan relay. (Marking: FAN NO. 1) I18027 Ohmmeter Ohmmeter 2 1 5 No Continuity Continuity (c) Inspect the No. 1 cooling fan relay continuity. (1) Using an ohmmeter, check that continuity exists between terminals 1 and 2. If no continuity exists, replace the relay. (2) Check that no continuity exists between terminals 3 and 5. If continuity exists, replace the relay. 3 B03548 (d) Ohmmeter 1 2 5 3 Battery Continuity Inspect the No. 1 cooling fan relay operation. (1) Apply battery voltage across terminals 1 and 2. (2) Using an ohmmeter, check that continuity exists between terminals 3 and 5. If no continuity exists, replace the relay. (e) Reinstall the No. 1 cooling fan relay. (f) Reinstall the relay box cover. B03549 2. (a) (b) INSPECT NO. 2 COOLING FAN RELAY Remove the relay box cover. Remove the No. 2 cooling fan relay. (Marking: FAN NO. 2) No. 2 Cooling Fan Relay I18027 1 Continuity Ohmmeter 4 2 Ohmmeter Ohmmeter 5 3 Continuity No Continuity B03550 (c) Inspect the No. 2 cooling fan relay continuity. (1) Using an ohmmeter, check that continuity exists between terminals 1 and 2. If no continuity exists, replace the relay. (2) Check that continuity exists between terminals 3 and 4. If no continuity exists, replace the relay. (3) Check that no continuity exists between terminals 3 and 5. If continuity exists, replace the relay. 2001 PRIUS (RM778U) Author: Date: 1305 CO–28 COOLING – COOLING FAN RELAY (d) 4 1 2 Battery Ohmmeter Ohmmeter 5 3 No Continuity Continuity No. 3 Cooling Fan Relay B03551 I18027 Ohmmeter Ohmmeter 2 1 Continuity 5 No Continuity Inspect the No. 2 cooling fan relay operation. (1) Apply battery voltage across terminals 1 and 2. (2) Using an ohmmeter, check that no continuity exists between terminals 3 and 4. If continuity exists, replace the relay. (3) Using an ohmmeter, check that continuity exists between terminals 3 and 5. If no continuity exists, replace the relay. (e) Reinstall the No. 2 cooling fan relay. (f) Reinstall the relay box cover. 3. INSPECT NO. 3 COOLING FAN RELAY (a) Remove the relay box cover. (b) Remove the No. 3 cooling fan relay. (Marking: Fan NO. 3) (c) Inspect the No. 3 cooling fan relay continuity. (1) Using an ohmmeter, check that continuity exists between terminals 1 and 2. If no continuity exists, replace the relay. (2) Check that no continuity exists between terminals 3 and 5. If continuity exists, replace the relay. 3 B03548 (d) Inspect the No. 3 cooling fan relay operation. (1) Apply battery voltage across terminals 1 and 2. (2) Using an ohmmeter, check that continuity exists between terminals 3 and 5. If no continuity exists, replace the relay. (e) Reinstall the No. 3 cooling fan relay. (f) Reinstall the relay box cover. Ohmmeter 2 1 5 Continuity Battery 3 B03549 2001 PRIUS (RM778U) Author: Date: 1306 LU–1 LUBRICATION – OIL AND FILTER OIL AND FILTER LU02K–08 Recommended Oil Viscosity (SAE): 10W – 30 5W – 30 PREFERRED °F °C –20 –29 0 –18 20 –7 40 4 60 16 80 27 100 38 TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE B00319 INSPECTION 1. CHECK ENGINE OIL QUALITY Check the oil for deterioration, entry of water, discoloring or thinning. If the quality is visibly poor, replace the oil. Oil grade: API grade or SJ, Energy–Conserving or ILSAC multigrade engine oil is recommended. SAE 5W–30 is the best choice for your vehicle, for good fuel economy, and good starting in cold weather. 2. CHECK ENGINE OIL LEVEL After warming up the engine and then 5 minutes after the engine stop, oil level should be between the ”L” and ”F” marks on the dipstick. If low. check for leakage and add oil up to the ”F” mark. NOTICE: Do not fill with engine oil above the ”F” mark. 3. Oil Pressure Switch (a) REMOVE OIL PRESSURE SWITCH, AND INSTALL OIL PRESSURE GAUGE Remove the oil pressure switch. B11764 (b) 4. Oil Pressure Gauge B11765 Install the oil pressure gauge. ACTIVATE INSPECTION MODE AND WARM UP ENGINE (See page IN–10) Allow the engine to warm up to normal operating temperature. 5. CHECK OIL PRESSURE Oil pressure: At idle speed 29 kPa (0.3 kgf/cm2, 4.3 psi) or more At 2,250 rpm 150 – 550 kPa (1.5 – 5.6 kgf/cm2, 22 – 80 psi) 6. REMOVE OIL PRESSURE GAUGE AND REINSTALL OIL PRESSURE SWITCH (a) Remove the oil pressure gauge. 2001 PRIUS (RM778U) Author: Date: 1307 LU–2 LUBRICATION (b) Adhesive (c) 7. – OIL AND FILTER Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No. 08833–00080, THREE BOND 1344, LOCTITE 242 or equivalent Install the oil pressure switch. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) START ENGINE AND CHECK FOR LEAKS P12478 2001 PRIUS (RM778U) Author: Date: 1308 LU–4 LUBRICATION – OIL PUMP OIL PUMP LU02M–08 COMPONENTS 26 (265, 19) Engine Coolant Reservoir Tank Wiper Arm 26 (265, 19) Brake reservoir Tank Cowl Top Ventilator Lower LH Heat to Cowl Top Seal Air Inlet Cowl Top Ventilator Lower LH 7 (71, 62 in. lbf) Air Cleaner Assembly Wiper Motor and Wiper Link Assembly R/B (ABS) Outer Front Cowl Top Panel VSV for EVAP 60 (612, 44) 52 (530, 38) RH Engine Mounting Insulator 52 (530, 38) Engine Under Cover RH N·m (kgf·cm, ft·lbf) : Specified torque A13942 2001 PRIUS (RM778U) Author: Date: 1310 LU–5 LUBRICATION – OIL PUMP RH Engine Mounting Bracket 15 (150, 11) Ignition Coil (w/ Ignitor) Timing Chain Cover Cylinder Head Cover 128 (1,300, 94) Pin PCV Hose Crankshaft Pulley 15 (150, 11)
Crankshaft Front Oil Seal Gasket Water Pump
Gasket 11 (110, 8) Water Pump Pulley
O–Ring
O–Ring N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part A13926 2001 PRIUS (RM778U) Author: Date: 1311 LU–6 LUBRICATION – OIL PUMP Timing Chain Cover Driven Rotor Oil Pump Cover Drive Rotor 10.3 (105, 8) 8.8 (90, 78 in.·lbf) Relief Valve Spring 25 (255, 18) N·m (kgf·cm, ft·lbf) : Specified torque B09334 2001 PRIUS (RM778U) Author: Date: 1312 IG–1 IGNITION – IGNITION SYSTEM IGNITION SYSTEM IG0EP–07 ON–VEHICLE INSPECTION NOTICE: ”Cold” and ”Hot” in these sentences express the temperature of the coils themselves. ”Cold” is from –10°C (14°F) to 50°C (122°F) and ”Hot” is from 50°C (122°F) to 100°C (212°F). 1. INSPECT IGNITION COIL (WITH IGNITER) AND SPARK TEST Check that the spark occurs. (1) Remove the ignition coils (with igniter) (See page IG–6). (2) Using a 16 mm (0.63 in.) plug wrench, remove the spark plugs. (3) Install the spark plugs to each ignition coils (with igniter), and connect the ignition coil connectors. (4) Disconnect the 4 injector connectors. (5) Ground the spark plugs. (6) Check if spark occurs while engine is being cranked. NOTICE: To prevent gasoline from being injected from injectors during this test, crank the engine for no more than 5 – 10 seconds at time. 2001 PRIUS (RM778U) Author: Date: 1318 IG–2 IGNITION – IGNITION SYSTEM If the spark does not occur, do the test as follows: SPARK TEST NO CHECK CONNECTION OF IGNITION COIL CONNECTOR Connect securely. BAD OK CHANGE IT TO NORMAL IGNITION COIL (WITH IGNITER) AND PERFORM SPARK TEST AGAIN Replace the ignition coil (with igniter). OK NO CHECK POWER SUPPLY TO IGNITION COIL (WITH IGNITER) 1. Turn ignition switch to ON. 2. Check that there is battery voltage at ignition coil positive (+) terminal. Check wiring between ignition switch to ignition coil (with igniter). BAD OK CHECK RESISTANCE OF CAMSHAFT POSITION SENSOR (See step 3) Cold Hot Resistance: 1,630 – 2,740 Ω 2,065 – 3.225 Ω Replace the camshaft position sensor. BAD OK CHECK RESISTANCE OF CRANKSHAFT POSITION SENSOR (See step 4) Cold Hot 1,265 – 1,890 Ω Resistance: 985 – 1,600 Ω Replace the crankshaft position sensor. BAD OK CHECK IGT SIGNAL FROM ECM (See page DI–115) BAD Check wiring between ECM and ignition coil (with igniter), and then try another ECM. OK TRY ANOTHER IGNITION COIL (WITH IGNITER) (7) 2. (a) (b) Using a 16 mm (0.63 in.) plug wrench, install the spark plugs. Torque: 18 N·m (184 kgf·cm, 13 ft·lbf) (8) Install the ignition coils (with igniter) (See page IG–7). INSPECT SPARK PLUGS Remove the ignition coils (with igniter) (See page IG–6). Using a 16 mm (0.63 in.) plug wrench, remove the spark plugs. 16 mm (0.63 in.) Plug Wrench B11755 2001 PRIUS (RM778U) Author: Date: 1319 IG–3 IGNITION – IGNITION SYSTEM (c) Clean the spark plugs. If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner. Air pressure: Below 588 kPa (6 kgf/cm2, 85 psi) Duration: 20 seconds or less HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner. IG0152 (d) Check the spark plug for thread damage and insulator damage. If abnormal, replace the spark plug. Recommended spark plug: DENSO made SK16R11 NGK made IFR5A11 IG0148 (e) B02101 Check the electrode gap. Electrode gap: 1.0 – 1.1 mm (0.039 – 0.043 in.) Maximum electrode gap: 1.2 mm (0.047 in.) If the electrode gap is greater than maximum, replace the spark plug. (f) Using a 16 mm (0.63 in.) plug wrench, install the spark plugs. Torque: 18 N·m (184 kgf·cm, 13 ft·lbf) (g) Install the ignition coils (with igniter) (See page IG–7). 3. (a) INSPECT CAMSHAFT POSITION SENSOR Disconnect the camshaft position sensor connector. (b) Using an ohmmeter, measure the resistance between terminals. Resistance: B11756 Cold 1,630 – 2,740 Ω Hot 2,065 – 3,225 Ω If the resistance is not as specified, replace the camshaft position sensor. (c) Connect the camshaft position sensor connector. B11757 2001 PRIUS (RM778U) Author: Date: 1320 IG–4 IGNITION – IGNITION SYSTEM 4. (a) (b) INSPECT CRANKSHAFT POSITION SENSOR Remove the engine under cover RH. While sliding the connector lock, remove the connector. (c) Using an ohmmeter, measure the resistance between the terminals. Resistance: B11758 B11759 Cold 985 – 1,600 Ω Hot 1,265 – 1,890 Ω If the resistance is not as specified, replace the crankshaft position sensor. (d) Install the connector. (e) Install the engine under cover RH. 2001 PRIUS (RM778U) Author: Date: 1321 HV–2 HYBRID VEHICLE CONTROL – HV BATTERY HV BATTERY HV002–01 COMPONENTS 4.0 (41, 35 in.·lbf) Inner Ventilator Duct Lower Quarter Ventilator Quarter Ventilator Duct 4.0 (41, 35 in.·lbf) 18 (185, 13) 18 (185, 13) x6 RH Battery Bracket Blower Motor Control Connector 18 (185, 13) x5 18 (185, 13) x6 HV Battery LH Battery Bracket 8.0 (80, 71 in.·lbf) Rear Seat Power Cable 5.0 (50, 44 in.·lbf) Battery Carrier Catch Bracket N·m (kgf·cm, ft·lbf) : Specified torque B11983 2001 PRIUS (RM778U) Author: Date: 1332 HV–3 HYBRID VEHICLE CONTROL – HV BATTERY 8.0 (80, 71 in.·lbf) 18 (185, 13) 6.0 (61, 53 in.·lbf) Battery Cover Busbar Module Protector Wire Harness Protector Busbar Module Service Plug Battery Hose 6.0 (61, 53 in.·lbf) Service Plug Assembly 3.3 (33, 29 in.·lbf) 5.0 (50, 44 in.·lbf) Battery ECU Battery Clamp Bolt RH Battery Bracket 5.0 (50, 44 in.·lbf) SMR SMR Cover 38 (390, 28) 38 (390, 28) Battery Module HV Battery Thermistor Busbar Module Battery Carrier Busbar Module Protector 5.0 (50, 44 in.·lbf) x38 x38 5.0 (50, 44 in.·lbf) N·m (kgf·cm, ft·lbf) : Specified torque B11984 2001 PRIUS (RM778U) Author: Date: 1333 HV–5 HYBRID VEHICLE CONTROL – HV BATTERY HV004–01 DISASSEMBLY 1. REMOVE BATTERY MODULE SET BOLT Turn the battery assembly upside down, remove the 76 battery module bolts. NOTICE: When turning it over, prevent the flange from being deformed. HINT: When not removing a battery module, skip the operation of step 1. 2. REMOVE BATTERY COVER Remove the 12 bolts, screw and battery cover. B11963 3. (a) (b) REMOVE SERVICE PLUG Remove the rear RH and LH busbar module protectors. Remove the 2 nuts for busbar module. (c) Remove the nut and wire harness protector. B11964 B11965 2001 PRIUS (RM778U) HV–6 HYBRID VEHICLE CONTROL – HV BATTERY (d) 4. (a) Remove the 3 bolts and service plug assembly. REMOVE POWER CABLE FOR SMR Remove the front RH and LH busbar module protectors. (b) Remove the 2 nuts, and disconnect the power cable from the front busbar module. Remove the SMR cover from the SMR. Remove 2 bolts, and disconnect the power cable for SMR. B12006 (c) (d) B11966 5. (a) REMOVE SMR Using the service plug, turn the interlock counterclockwise to unlock. NOTICE: When the interlock is damaged, be sure to replace it with new one. (b) Remove the 3 bolts and SMR. B11967 6. 7. (a) REMOVE HV BATTERY THERMISTOR REMOVE BATTERY ECU Disconnect the connector. (b) Remove the 2 bolts and battery ECU. B11968 B11969 2001 PRIUS (RM778U) HV–7 HYBRID VEHICLE CONTROL 8. 9. (a) (b) – HV BATTERY REMOVE BATTERY HOSE REMOVE BUSBAR MODULE Remove the 36 nuts, RH and LH rear busbar modules. Remove the 36 nuts, RH and LH front busbar modules. B11970 10. REMOVE BATTERY CLAMP BOLT Remove the 4 bolts and battery clamp bolt. CAUTION: Never remove the battery clamp bolt until 4 hours has passed after the ignition switch is turned OFF. An explosion due to expansion could occur. B11971 11. REMOVE RH BATTERY BRACKET Remove the 2 bolts and RH battery bracket. CAUTION: Never remove the RH battery bracket until 4 hours has passed after the ignition switch is turned OFF. An explosion due to expansion could occur. 12. REMOVE 38 HV BATTERY MODULES B11972 2001 PRIUS (RM778U) HV–9 HYBRID VEHICLE CONTROL – HV BATTERY HV006–01 REASSEMBLY 1. INSTALL BATTERY MODULE Install the 38 battery modules to the battery carrier. HINT:
Packs containing 2 battery module each are arranged in the order of 1 to 19 from the ECU side.
Starting from the positive terminal of the battery module on the battery ECU side, install 38 battery modules by alternately connecting the positive and negative terminals to the vehicle front side. 2. INSTALL BATTERY CLAMP BOLT Install the battery clamp bolt with the 2 bolts. Torque: 23 N·m (230 kgf·cm, 16 ft·lbf) B11973 3. INSTALL RH BATTERY BRACKET Install the RH battery bracket with the 4 bolts. Torque: 23 N·m (230 kgf·cm, 16 ft·lbf) B11974 4. B11970 2001 PRIUS (RM778U) 4/6/01 INSTALL BATTERY HOSE HV–10 HYBRID VEHICLE CONTROL – HV BATTERY 5. INSTALL HV BATTERY THERMISTOR 6. (a) INSTALL BATTERY ECU Install the battery ECU with the 2 bolts. Torque: 3.3 N·m (33 kgf·cm, 29 in.·lbf) Connect the connector for HV battery thermistor. INSTALL BUSBAR MODULE Install the front busbar module with the 74 nuts. Torque: 6.0 N·m (61 kgf·cm, 53 in.·lbf) Install the rear RH and LH busbar modules with the 74 nuts. Torque: 6.0 N·m (61 kgf·cm, 53 in.·lbf) INSTALL SMR Install the SMR with the 3 bolts. Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf) Connect the power cable for SMR with the 2 bolts. Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf) Install the SMR cover to the SMR. Connect the connector to the cover for external uniform charger and lock the cover. B11968 (b) 7. (a) (b) B11969 8. (a) (b) (c) (d) B11967 (e) (f) Connect the power cable for SMR with the 2 nuts. Torque: 6.0 N·m (61 kgf·cm, 53 in.·lbf) Install the front RH and LH busbar module protectors. B11966 9. (a) B12006 2001 PRIUS (RM778U) 4/6/01 INSTALL SERVICE PLUG Install the service plug with the 3 bolts. Torque: 6.0 N·m (61 kgf·cm, 53 in.·lbf) HV–11 HYBRID VEHICLE CONTROL – HV BATTERY (b) Install the wire harness protector with the nut. (c) Install the busbar module with 2 new nuts. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) INSTALL REAR RH AND LH BUSBAR MODULE PROTECTOR B11965 10. B11964 A A A B B B Screw A 2001 PRIUS (RM778U) 4/6/01 A C B11963 11. INSTALL BATTERY COVER Install the battery cover with the 12 bolts and screw. Torque: Bolt A: 18 N·m (185 kgf·cm, 13 ft·lbf) Bolt B: 8.0 N·m (80 kgf·cm, 71 in.·lbf) Bolt C: 7.0 N·m (70 kgf·cm, 62 in.·lbf) Screw: 6.0 N·m (61 kgf·cm, 53 in.·lbf) 12. INSTALL BATTERY MODULE SET BOLT Turn the battery assembly upside down, install the 76 battery module set bolts. Torque: 4.0 N·m (40 kgf·cm, 35 in.·lbf) HV–12 HYBRID VEHICLE CONTROL – HV BATTERY HV007–01 INSTALLATION 1. INSTALL HV BATTERY (a) Set the HV battery to the body. (b) Connect the battery hose to the body. CAUTION: Since alkaline electrolyte may be got on the hose end, carry out the operation with considera care. 2. (a) INSTALL BATTERY BRACKET Install the RH and LH battery bracket with the 13 bolts and nut. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) (b) Install and tighten the 5 bolts for HV battery. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) 3. (a) (b) INSTALL HIGH TENSION CABLE Install the earth terminal. Install the high tension cable with the 2 bolts. Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf) B11992 B11962 B11961 (c) B11960 2001 PRIUS (RM778U) Install the battery carrier catch bracket with the 3 nuts. Torque: 8.0 N·m (80 kgf·cm, 71 in.·lbf) NOTICE: When installing a cover, never fail to pass the interlock button. 4. INSTALL DUCT (See page HV–32) 5. CONNECT CONNECTOR (a) Connect the 2 connectors to the battery ECU. (b) Connect the connector to the SMR. (c) Connect the connector to the service plug assembly. HV–13 HYBRID VEHICLE CONTROL 6. 7. 8. 2001 PRIUS (RM778U) – HV BATTERY INSTALL REAR SET (See page BO–82) INSTALL LUGGAGE TRIM (See page BO–25) INSTALL SERVICE PLUG (See page HV–1) HV–14 HYBRID VEHICLE CONTROL – CONVERTER AND INVERTER ASSEMBLY CONVERTER AND INVERTER ASSEMBLY HV008–02 ON–VEHICLE INSPECTION 1. (a) (b) (c) INSPECT INVERTER Turn the IG switch OFF and disconnect the 4 connectors. Apply battery positive voltage to connector B terminal 5 (IGCT) on the inverter side through a fuse, and battery negative voltage to connector B terminal 6 (GND). Measure the voltage and resistance between each terminal shown below and ground. B A 4321 8765 3 21 654 C 4 3 21 87 6 5 D 3 21 6 54 B12008 Terminal Measuring Condition Specification A, 5 (G – INVT) D, 5 (M–INVT) – Approx. 2 – 4.5 V C, 5 (VB) – Approx. 0.5 – 4 V A, 4 (G – SDOWN) D, 4 (M – SDOWN) Apply battery positive voltage to terminal through the resistance of 1 kΩ. Approx. 5 – 6 V B, 8 (G – FINV) C, 8 (M – FINV) B, 7 (G – SINV) C, 7 (M – SINV) Connect the terminal to connector B terminal 6 through the resistance of 10 kΩ. 7 – 12 V approx. 0.2 sec. A, 1 (G – UU) A, 2 (G – VU) A, 3 (G – WU) D, 1 (M – UU) D, 2 (M – VU) D, 3 (M – WU) Connect the terminal to connector B terminal 6 through the resistance of 1 kΩ. Approx. 6 – 8 V B, 1 (G – IVA) B, 2 (G – IWA) B, 3 (G – IVB) B, 4 (G – IWB) C, 1 (M – IVA) C, 2 (M – IWA) C, 3 (M – IVB) C, 4 (M – IWB) – Approx. 0 V B, 6 (GND) A, 6 (G – GINV) D, 6 (M – GINV) – Continuity C, 6 (CVRSW) Install a cover for the connecting part of the power cable for the MG1 and MG2. Continuity 2001 PRIUS (RM778U) Author: Date: 1344 HV–15 HYBRID VEHICLE CONTROL 2. (a) (b) B12009 – CONVERTER AND INVERTER ASSEMBLY INSPECT CONVERTER Function check Measure the voltage of an auxiliary battery terminal when the ”READY” lamp is OFF and ON. READY lamp is OFF: Approx. 12 V READY lamp is ON: Approx. 14 V Output current check (1) Disconnect the MG2 power cable from the inverter (See page HV–18). (2) Install AC/DC 400 A probe to the wire harness of the IP connector of the converter. (3) Connect the MG2 power cable to the inverter (See page HV–22). (4) With the READY lamp ON, operate electric devices one by one and measure the output current. Standard: 100 A or less HINT: If more than 100 A is shown momentarily, check for the followings.
Ground short of electric device.
Overload caused by installation of excessive device.
PTC heater operation. 2001 PRIUS (RM778U) Author: Date: 1345 HV–16 HYBRID VEHICLE CONTROL – CONVERTER AND INVERTER ASSEMBLY HV009–01 COMPONENTS Cowl Top Panel Wiper Arm and Blade Assembly Wiper Motor w/ Wiper Link Cowl Top Ventilator Louver Power Cable Connector Hood to Cowl Top Seal Converter Connector Inverter Connector Inverter Terminal Cover 8.0 (82, 71 in.·lbf)
Gasket Water Hose 8.0 (82, 71 in.·lbf) 19.5 (199, 14) MG2 Power Cable 7.0 (71, 62 in.·lbf) 20 (204, 15) Water Hose 21 (214, 15) 8.0 (82, 71 in.·lbf) Converter & Inverter Assembly N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part 2001 PRIUS (RM778U) Circuit Breaker Sensor Connector Cover MG1 Power Cable B11975 HV–17 HYBRID VEHICLE CONTROL – Upper Inverter Cover CONVERTER AND INVERTER ASSEMBLY 2.5 (25, 22 in.·lbf)
Gasket 8.0 (82, 71 in.·lbf) Inverter Reservoir Tank
25 (255, 18)
O–ring 8.0 (82, 71 in.·lbf) Water Hose Bracket Bracket
Bracket 25 (255, 18)
25 (255, 18) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part 2001 PRIUS (RM778U) B11976 HV–18 HYBRID VEHICLE CONTROL – CONVERTER AND INVERTER ASSEMBLY HV00A–01 REMOVAL 1. 2. 3. REMOVE SERVICE PLUG (See page HV–1) DRAIN HV COOLANT (See page HT–6) REMOVE COWL TOP PANEL (See page BO–31) 4. VERIFY 0 V NOTICE:
Before starting step (a), 5 minutes or more should be passed after removing the service plug.
Be careful to prevent foreign matter from entering the inside of connector cover. (a) Disconnect the connector of the battery power cable and insulate it with packaging tape. (b) Using a torx socket wrench (T30), remove the 4 screws and inverter terminal cover. (c) Using a torx socket wrench (T40), remove the 2 screws, circuit breaker sensor and connector cover. HINT: Slide the connector cover to disconnect the circuit breaker sensor connector. (d) Using a voltmeter, measure the voltage between terminals of 3 phases (U–V, V–W, U–W) and each terminal and body ground to verify them to be approx. 0 V. B11977 5. REMOVE CONVERTER & INVERTER ASSEMBLY (a) Remove the 6 bolts and 3 power cables for MG2. NOTICE: Be careful to prevent foreign matter from entering the inside of connector cover. B11979 (b) Remove the 3 bolts and power cable for MG1. NOTICE:
Remove the power cable for MG1 together with converter & inverter assembly.
Be careful to prevent foreign matter from entering the inside of connector cover. (c) Remove the bolt and ground cable. B11980 2001 PRIUS (RM778U) HV–19 HYBRID VEHICLE CONTROL (d) Water Hose (e) Water Hose B11978 2001 PRIUS (RM778U) – CONVERTER AND INVERTER ASSEMBLY Disconnect the 3 water hoses from the converter & inverter assembly. Remove the 4 bolts and converter & inverter assembly. HV–22 HYBRID VEHICLE CONTROL – CONVERTER AND INVERTER ASSEMBLY HV00D–01 INSTALLATION 1. (a) (b) (c) (d) INSTALL CONVERTER & INVERTER ASSEMBLY Install the converter & inverter assembly with the 4 bolts. Torque: 21 N·m (214 kgf·cm, 15 ft·lbf) Connect the 3 water hoses to the converter & inverter assembly. Connect the 4 connectors. Connect the 2 power cable connectors. B11978 (e) Install the ground cable to the radiator upper support. Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf) (f) Install the power cable for MG1 with the 3 bolts. Torque: 7.0 N·m (71 kgf·cm, 62 in.·lbf) NOTICE: Be careful to prevent foreign matter from entering the inside of connector cover. B11980 (g) (h) Install the connector cover and circuit breaker sensor with the2 screws. Torque: 20 N·m (204 kgf·cm, 15 ft·lbf) Connect the connector for circuit breaker sensor. B12004 (i) Install the 3 power cables for MG2 with the 6 bolts. Torque: Bolt A: 19.5 N·m (199 kgf·cm, 14 ft·lbf) Bolt B: 8.0 N·m (82 kgf·cm, 71 in.·lbf) NOTICE: Be careful to prevent foreign matter from entering the inside of connector cover. A A A B B B B11979 (j) 2. 3. 4. B12005 2001 PRIUS (RM778U) Install the gasket and inverter terminal cover with the 4 screws. Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf) INSTALL COWL TOP PANEL (See page BO–31) INSTALL SERVICE PLUG (See page HV–1) FILL WITH HV COOLANT (See page HT–6) HV–23 HYBRID VEHICLE CONTROL 5. – CONVERTER AND INVERTER ASSEMBLY OPERATION AFTER REPLACING CONVERTER & INVERTER ASSEMBLY Even if the master warning light is not lit, clear DTC using a TOYOTA hand–held tester. When replacing a converter & inverter assembly of the vehicle in which no error occurs, also clear DTC using a TOYOTA hand held tester. HINT: When a TOYOTA hand–held tester cannot be used, disconnect the auxiliary battery for 1 min. or more and connect it again. 6. CHECKING AFTER REPLACING CONVERTER & INVERTER ASSEMBLY Depressing the accelerator pedal to a degree of 50 %, increase the speed up to approx. 15 km/h 3 or 4 times to check that there is no problem in the inverter operation. 2001 PRIUS (RM778U) HT–3 HYBRID TRANSAXLE – OIL PUMP ASSEMBLY OIL PUMP ASSEMBLY HT003–01 ON–VEHICLE REPAIR 1. REMOVE ENGINE UNDER COVER LH 2. (a) (b) REMOVE OIL PUMP Remove the plug. Remove the O–ring from the plug. (c) Remove the 5 bolts and oil pump cover. (d) Remove the O–ring. (e) Remove the oil pump driven rotor and drive rotor. D09721 D09722 O–Ring D09723 D09724 2001 PRIUS (RM778U) Author: Date: 1376 HT–4 HYBRID TRANSAXLE – OIL PUMP ASSEMBLY (f) 3. (a) (b) Remove the oil pump drive shaft. INSTALL OIL PUMP Apply ATF to each sliding part. Install the oil pump drive shaft. (c) Install the oil pump driven rotor and drive rotor. (d) Install a new O–ring. (e) Apply liquid sealer to 2 or 3 threads of the bolt end. Sealant: Part No. 08833–00080, THREE BOND 1344, LOCTITE 242 or equivalent Install the oil pump cover with the 5 bolts. Torque: 5.5 N·m (56 kgf·cm, 49 in.·lbf) D09725 D09724 O–Ring D09723 (f) D09722 (g) 4. Install a new O–ring and the plug. Torque: 7.35 N·m (75 kgf·cm, 65 in.·lbf) INSTALL ENGINE UNDER COVER LH D09721 2001 PRIUS (RM778U) Author: Date: 1377 HT–6 HYBRID TRANSAXLE – HYBRID TRANSAXLE UNIT HYBRID TRANSAXLE UNIT HT005–01 ON–VEHICLE REPAIR Drain Plug 1. REPLACE TRANSAXLE OIL Fluid type: ATF Type T–IV Capacity: 4.6 liters (4.9 US qts, 4.0 Imp. qts) Torque: 49 N·m (498 kgf·cm, 36 ft·lbf) 2. (a) (b) (c) REPLACE COOLANT Remove the reservoir tank cap of the inverter. Remove the drain plug and drain the coolant. Install the drain plug with a new gasket. D09920 Oil Level 0 – 5 mm D09925 Drain Plug D09921 (d) Loosen the 2 bleeder plugs and connect the hoses. HINT: To prevent coolant from splashing, place a shop rag on the overflow pipe as shown in the illustration. (e) Supply coolant from the reservoir tank. Shop Rag D09778 (f) D09899 (g) (h) (i) (j) (k) (l) Supply coolant until coolant level in the hose connected to the bleeder plugs reaches the same level with FULL of the reservoir tank as shown in the illustration. Tighten the 2 bleeder plugs. Turn the ignition switch ON and active the water pump. Leave it as it is for approx. 20 seconds. Turn the ignition switch OFF. Loosen the 2 bleeder plugs to bleed air. Close the 2 bleeder plugs again. 2001 PRIUS (RM778U) Author: Date: 1379 HT–7 HYBRID TRANSAXLE (m) (n) (o) – HYBRID TRANSAXLE UNIT Report the step (h) to (l) until the operation sound of the pump becomes lower and Coolant in the reservoir tank moves faster. With the ignition switch ON, wait for applox. 5 minutes. Adjust the coolant level inside the reservoir tank as shown in the illustration. Coolant Level D09898 2001 PRIUS (RM778U) Author: Date: 1380 HT–12 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY HYBRID TRANSAXLE ASSEMBLY HT00A–01 COMPONENTS Power Cable Cover 18 (183, 13) Housing Tube 4.8 (48, 42 in.·lbf) 15 (152, 11) 5.5 (56, 49 in.·lbf) 25 (250, 18) Screw Plug High–Voltage Cable 12.7 (130, 9) x 13
Oil Seal 5.5 (56, 49 in.·lbf) Lock Sleeve Cam Guide Sleeve Motor Generator No. 1 Assembly Sleeve Bracket Parking Lock Pawl Water Jacket Union 13 (130, 9) 50 (510, 37) Torsion Spring Wiring Harness Connector Lock Clamp Parking Lock Pawl Shaft 5.5 (56, 49 in.·lbf) 5.4 (55, 48 in.·lbf)
Gasket Counter Driven Gear Assembly Outer Race Drain Plug Shim 39 (400, 29) Outer Race Outer Race Counter Drive Gear Assembly Differential Case Assembly Shim Outer Race Chain Shim Needle Roller Bearing Drive Sprocket Bearing Race Planetary Ring Gear Needle Roller Bearing Input Shaft Assembly Bearing Race Shim Ring Gear Flange N·m (kgf·cm, in.·lbf) : Specified torque
Non–reusable part D09787 2001 PRIUS (RM778U) Author: Date: 1385 HT–13 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY 13 (130, 10) x5
Oil Seal Parking Shaft Cover Motor Water Jacket Cover Washer Parking Lock Shaft Pin x6 5.5 (56, 49 in.·lbf)
Spacer Parking Lock Lever No. 3 Breather Plug Screw Plug Filler Plug 11.3 (111, 8) 24.5 (250, 18) 39 (400, 29) 52 (530, 38)
Gasket Motor Generator No. 2 Assembly Mounting Bracket Detent Spring Detent Spring Cover Screw Plug 5.5 (56, 49 in.·lbf) 24.5 (250, 18) 25 (250, 18) x8 x6 Water Jacket Union
Gasket 5.5 (56, 49 in.·lbf) 10 (100, 7) Filler Plug 5.5 (56, 49 in.·lbf) 39 (400, 29) Oil Pump Drive Shaft Oil Strainer Wiring Harness Connector Parking Cover
Oil Seal 50 (510, 37) Wiring Harness Connector Driven Rotor
O–Ring Magnet 5.5 (56, 49 in.·lbf)
Gasket x5 Drive Rotor 5.5 (56, 49 in.·lbf)
O–Ring Oil Pan
Gasket
O–Ring x 12 Oil Pump Cover 7.6 (77, 67 in.·lbf) Plug Drain Plug 7.35 (75, 65 in.·lbf) 49 (498, 36) N·m (kgf·cm, in.·lbf) : Specified torque
Non–reusable part D09916 2001 PRIUS (RM778U) Author: Date: 1386 HT–14 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY HT00B–01 DISASSEMBLY D09694 1. INSTALL ENGINE HUNGER Install the engine hanger onto the MG1 side as shown in the illustration, and lift it up by a chain device. Engine hanger part No.: 12281–67070, S1228–11781 Bolt part No.: 91642–81045 91642–81265 2 pieces Nut part No.: 90178–10001 90179–12147 2 pieces NOTICE:
As the transaxle itself is heavy, place a wood block underneath to stabilize it and carry out the operation carefully.
Do not pull or bend the high–voltage cable of the MG1 assembly.
Drain the fluid before disassembly. 2. (a) REMOVE MG1 ASSEMBLY Remove the 21 bolts. (b) Using a screwdriver and a hammer, disconnect the MG1 assembly from the MG2 assembly. D09695 D09696 2001 PRIUS (RM778U) HT–15 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY HINT: When separating the MG1 assembly from the MG2 assembly, to prevent the drive sprocket from being removed with the MG1 assembly, push down the chain part with a taped screwdriver tip. D09697 3. REMOVE COUNTER DRIVEN GEAR ASSEMBLY Remove the counter driven gear assembly from the MG2 assembly. D09698 4. REMOVE DIFFERENTIAL CASE ASSEMBLY Remove the differential case assembly from the MG2 assembly. D09699 5. REMOVE 2 RACE AND NEEDLE ROLLER BEARING 6. REMOVE DRIVE SPROCKET SUB–ASSEMBLY AND CHAIN D09926 D09700 2001 PRIUS (RM778U) HT–16 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY 7. (a) REMOVE INPUT SHAFT ASSEMBLY Remove the input shaft assembly. (b) Remove the needle roller bearing and 2 bearing races. 8. REMOVE PLANETARY RING GEAR 9. REMOVE RING GEAR FLANGE AND SHIM D09701 D09702 D09703 D09704 10. REMOVE COUNTER DRIVE GEAR AND SHIM HINT: Remove the counter drive gear by tapping the case with a plastic hammer. D09705 2001 PRIUS (RM778U) HT–17 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY 11. (a) (b) (c) REMOVE OIL PAN AND GASKET Remove the drain plug and its gasket. Remove the 12 bolts. Remove the oil pan and its gasket. 12. REMOVE MAGNET FROM OIL PAN D09706 D09884 13. EXHAUST PARTICLES IN PAN Remove the magnet and use it to collect any steel chips. Carefully examine the chips and particles in the oil pan and on the magnet to indentify what type of wear has occurred in the transaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non–magnetic): bushing wear AT0103 14. (a) REMOVE OIL STRAINER Remove the bolt and oil strainer. (b) Remove the O–ring from the oil strainer. D09707 D09883 2001 PRIUS (RM778U) HT–18 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY 15. SET MG2 ASSEMBLY As illustrated, set the MG2 assembly and wood blocks. D09708 16. REMOVE MOUNTING BRACKET Remove the 3 bolts and mounting bracket. D09709 17. REMOVE WIRING HARNESS CONNECTOR (MG2 side) Remove the 2 bolts and the 2 wiring harness connectors. D09710 18. REMOVE 2 WATER JACKET UNIONS (MG2 side) D09711 19. REMOVE PARKING COVER Remove the 6 bolts and parking cover. D09712 2001 PRIUS (RM778U) HT–19 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY 20. REMOVE DETENT SPRING COVER AND DETENT SPRING Remove the bolt, detent spring cover and detent spring. D09713 21. REMOVE MOTOR WATER JACKET COVER Remove the 6 bolts and motor water jacket cover. D09714 22. (a) REMOVE PARKING SHAFT COVER Remove the 5 bolts and parking shaft cover. (b) Using a screwdriver, remove the oil seal from the cover. 23. REMOVE PARKING LOCK SHAFT ASSEMBLY D09715 D09716 D09717 2001 PRIUS (RM778U) HT–20 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY 24. (a) DISASSEMBLE PARKING LOCK SHAFT ASSEMBLY Remove the washer. (b) (c) Using a chisel and a hammer, cut the spacer. Remove the spacer. (d) (e) Using a pin punch and a hammer, drive out the pin. Remove the parking lock lever No. 3 from the parking lock shaft. 25. (a) (b) REMOVE OIL PUMP Remove the plug. Remove the O–ring from the plug. (c) Remove the 5 bolts and oil pump cover. D09718 D09719 D09720 D09721 D09722 2001 PRIUS (RM778U) HT–21 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY (d) Remove the O–ring. (e) Remove the oil pump driven rotor and drive rotor. (f) Remove the oil pump drive shaft. O–Ring D09723 D09724 D09725 26. REMOVE DIFFERENTIAL SIDE BEARING OUTER RACE LH AND SHIM (MG2 side) Using SST, drive out the differential side bearing outer race and shim. SST 09308–00010 SST D09726 27. (a) SST D09727 2001 PRIUS (RM778U) REMOVE COUNTER DRIVEN GEAR SIDE BEARING OUTER RACE LH AND SHIM Using SST, drive out the counter driven gear side bearing outer race and shim. SST 09308–00010 HT–22 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY (b) Overturn the MG2 assembly and place a wood block under it stabilize. NOTICE: Be careful not to bend the parking lock rod. D09924 28. REMOVE DIFFERERENTIAL OIL SEAL LH (MG2 side) Using a screwdriver, drive out the oil seal. D09729 29. Filler Plug (a) (b) REMOVE FILLER PLUG AND SCREW PLUG (MG2 side) Remove the 2 screw plugs with a hexagon wrench. Remove the 2 filler plugs and the 2 gaskets. 30. REMOVE BREATHER PLUG 31. PLACE WOOD BLOCK UNDER MG1 ASSEMBLY TO STABILIZE Screw Plug D09793 D09936 D09730 2001 PRIUS (RM778U) HT–23 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY 32. (a) REMOVE HIGH–VOLTAGE CABLE Remove the 4 bolts and power cable cover. (b) Remove the 6 bolts and the high–voltage cable. D09731 D09732 33. REMOVE WIRING HARNESS CONNECTOR (MG1 side) Remove the bolt and wiring harness connector. D09733 34. REMOVE 2 WATER JACKET UNIONS (MG1 side) 35. REMOVE HOUSING TUBE D09734 D09735 2001 PRIUS (RM778U) HT–24 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY 36. REMOVE INPUT SHAFT OIL SEAL Using SST, drive out the input shaft oil seal. SST 09612–30012 SST D09736 37. REMOVE DIFFERENTIAL OIL SEAL RH (MG1 side) Using a screwdriver, drive out the differential oil seal RH. 38. TURN MG1 ASSEMBLY UPSIDE DOWN D09737 39. (a) REMOVE PARKING LOCK PAWL Remove the bolt and the lock clamp. (b) (c) Remove the parking lock pawl shaft. Remove the parking lock pawl. 40. (a) REMOVE PARKING LOCK SLEEVE Remove the 2 bolts, sleeve bracket, torsion spring and parking lock sleeve. D09739 D09740 D09741 2001 PRIUS (RM778U) HT–25 HYBRID TRANSAXLE (b) – HYBRID TRANSAXLE ASSEMBLY Remove the cam guide sleeve from the sleeve bracket. D09742 41. SST REMOVE COUNTER DRIVEN GEAR SIDE BEARING OUTER RACE RH (MG1 side) Using SST, drive out the counter driven gear side bearing outer race RH. SST 09308–00010 D09743 42. REMOVE DIFFERENTIAL SIDE BEARING OUTER RACE RH (MG1 side) Using SST, drive out the differential side bearing outer race RH. SST 09308–00010 SST D09744 43. Screw Plug (a) (b) Drain Plug D09792 2001 PRIUS (RM778U) REMOVE DRAIN PLUG AND SCREW PLUG (MG1 side) Remove the screw plug from the MG1 assembly with a hexagon wrench. Remove the drain plug and the gasket. HT–26 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY HT00C–02 REASSEMBLY D09935 1. INSPECT ROTOR BUSH OF MG2 ASSEMBLY Using a dial indicator, measure the inside diameter of the rotor bush. Standard diameter: 20.025 – 20.046 mm (0.78838 – 0.78921 in.) Maximum diameter: 20.096 mm (0.79118 in.) If the inside diameter exceeds the limit, replace the MG2 assembly. 2. PLACE WOOD BLOCK UNDER MG1 ASSEMBLY TO STABILIZE 3. (a) INSTALL DRAIN PLUG AND SCREW PLUG (MG1 side) Apply liquid sealer to the screw plug and install it to the MG1 assembly with a hexagon wrench. Sealant: Part No. 08833–00080, TREE BOND 1344, LOCTITE 242 or equivalent Torque: 12.7 N·m (130 kgf·cm, 9 ft·lbf) Install a new gasket and the drain plug. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) D09730 Drain Plug Screw Plug (b) D09928 4. PLACE WOOD BLOCK UNDER MG2 ASSEMBLY NOTICE: Be careful not to bend the parking lock rod. D09937 2001 PRIUS (RM778U) HT–27 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY 5. Filler Plug Screw Plug B Screw Plug A D09793 INSTALL FILLER PLUG AND SCREW PLUG (MG2 side) (a) Apply liquid sealer to the 2 screw plugs and install them to the MG2 assembly with a hexagon wrench. Sealant: A: Part No. 08833–00070, THREE BOND 1324 or equivalent B: Part No. 08833–00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 24.5 N·m (250 kgf·cm, 18 ft·lbf) NOTICE: Be careful not to bend the parking lock rod. (b) Install 2 new gaskets and the 2 filler plugs. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) 6. (a) SST (b) INSTALL DIFFERENTIAL OIL SEAL RH (MG1 side) Using SST and a hammer, install a new oil seal. SST 09710–20011 (09710–06071), 09950–70010 (09951–07100) Oil seal depth: 2.7 ± 0.5 mm (0.106 ± 0.020 in.) Coat the lip of the oil seal with MP grease. D09882 7. (a) SST (b) INSTALL DIFFERENTIAL OIL SEAL LH (MG2 side) Using SST and a hammer, install a new oil seal LH. SST 09710–20011 (09710–06071), 09950–70010 (09951–07100) Oil seal depth: 2.7 ± 0.5 mm (0.106 ± 0.020 in.) Coat the lip of the oil seal with MP grease. D09728 8. D09936 2001 PRIUS (RM778U) INSTALL BREATHER PLUG Torque: 11.3 N·m (111 kgf·cm, 8 ft·lbf) HT–28 HYBRID TRANSAXLE D09852 – HYBRID TRANSAXLE ASSEMBLY 9. INSTALL OUTER RACE AND SHIM HINT: If there is some diformation or scratch to the outer race and shim, replace each of them by a new one. (a) Place a wood block under the MG2 assembly to stabilize. NOTICE:
Set the MG2 assembly horizontally.
Unreasonable force should not be applied to the high–voltage cable. (b) SST MG2 side: Using SST and a hammer, install the outer race of differential side bearing LH and shim. SST 09950–60020 (09951–00680), 09950–70010 (09951–07100) HINT: If replacing the shim, install a new shim which has the same thickness with the removed. D09853 (c) SST MG2 side: Using SST and a hammer, install the tapered roller bearing outer race LH of the counter driven gear and shim. SST 09950–60020 (09951–00680), 09950–70010 (09951–07100) HINT: If replacing the shim, install a new shim which has the same thickness with the removed. D09854 (d) MG1 side: Using SST and a hammer, install the side bearing outer race RH of the differential. SST 09950–60020 (09951–00680), 09950–70010 (09951–07100) (e) MG1 side: Using SST and a hammer, install the tapered roller bearing outer race RH of the counter driven gear. SST 09950–60020 (09951–00680), 09950–70010 (09951–07100) SST D08194 SST D09855 2001 PRIUS (RM778U) HT–29 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY 10. INSTALL DIFFERENTIAL TO MG2 ASSEMBLY (a) Install the differential assembly to the MG2 assembly. HINT: Apply ATF to the side bearing. D09857 (b) Install the engine hanger onto the MG1 side as shown in the illustration, and lift it up by a chain device. Engine hanger part No.: 12281 – 67070, S1228 – 11781 Bolt part No.: 91642 – 81045 91642 – 81265 2 pieces Nut part No.: 90178 – 10001 90179 – 12147 2 pieces (c) Install the 13 bolts and MG1 assembly to the MG2 assembly. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) (d) Using SST, rotate the differential case assembly in both directions to make it fit. SST 09564–32011 D09694 D09695 SST D09858 2001 PRIUS (RM778U) HT–30 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY (e) SST D09859 Using SST and a small torque wrench, measure the differential preload. SST 09564–32011 Preload (Starting torque): New bearing 0.98 – 1.57 N·m (9.99 – 16.01 kgf·cm, 8.67 – 13.90 in.·lbf) Reused bearing 0.49 – 0.78 N·m (5.00 – 7.95 kgf·cm, 4.34 – 6.90 in.·lbf) Preload (Turning torque): 0.78 – 1.37 N·m (60 rpm) (7.95 – 13.97 kgf·cm, 6.90 – 12.13 in.·lbf) If the preload is not within the specified range, replace the shim of the differential outer race LH. Shim thickness: Mark Thickness mm (in.) Mark Thickness mm (in.) 1 1.80 (0.0709) 61 2.14 (0.0843) 2 1.83 (0.0720) 62 2.16 (0.0850) 3 1.86 (0.0732) 63 2.18 (0.0858) 4 1.89 (0.0744) 64 2.20 (0.0866) 50 1.92 (0.0756) 65 2.22 (0.0874) 51 1.94 (0.0764) 66 2.24 (0.0882) 52 1.96 (0.0772) 67 2.26 (0.0890) 53 1.98 (0.0780) 68 2.28 (0.0898) 54 2.00 (0.0787) 69 2.30 (0.0906) 55 2.02 (0.0795) 70 2.32 (0.0913) 56 2.04 (0.0803) 19 2.34 (0.0921) 57 2.06 (0.0811) 20 2.37 (0.0933) 58 2.08 (0.0819) – 2.40 (0.0945) 59 2.10 (0.0827) 22 2.43 (0.0957) 60 2.12 (0.0835) 23 2.46 (0.0969) HINT: As a rank of shim thickness is increased (0.020 mm), the preload of approx. 0.23 N·m (2.4 kgf·cm, 2.1 in.·lbf) is increased accordingly. 11. INSTALL COUNTER DRIVEN GEAR TO MG2 ASSEMBLY (a) Remove the 13 bolts, separate the MG1 assembly and the MG2 assembly. 2001 PRIUS (RM778U) HT–31 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY (b) Install the counter driven gear to the MG2 assembly. HINT: Apply ATF to the side bearing. D09860 (c) Install the engine hanger onto the MG1 side as shown in the illustration, and lift it up by a chain device. Engine hanger part No.: 12281 – 67070, S1228 – 11781 Bolt part No.: 91642 – 81045 91642 – 81265 2 pieces Nut part No.: 90178 – 10001 90179 – 12147 2 pieces (d) Install the MG1 assembly to the MG2 assembly with the 13 bolts. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) (e) Using SST, rotate the differential case assembly in both directions to make it fit. SST 09564–32011 D09694 D09695 SST D09858 2001 PRIUS (RM778U) HT–32 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY (f) SST D09859 Using SST and a small torque wrench, measure the counter driven gear preload. SST 09564–32011 Preload (Starting torque): New bearing 3.81 – 6.10 N·m (38.85 – 62.20 kgf·cm, 33.72 – 53.99 in.·lbf) Reused bearing 1.91 – 3.03 N·m (19.48 – 30.90 kgf·cm, 16.91 – 26.82 in.·lbf) Preload (Turning torque): 3.29 – 6.66 N·m (60 rpm) (33.55 – 67.91 kgf·cm, 29.12 – 58.95 in.·lbf) If the preload is not within the specified range, replace the shim of the counter driven gear LH. Shim thickness: Mark Thickness mm (in.) Mark Thickness mm (in.) 1 1.25 (0.0492) 62 1.58 (0.0622) 2 1.28 (0.0504) 63 1.60 (0.0630) 3 1.31 (0.0516) 64 1.62 (0.0638) 50 1.34 (0.0528) 65 1.64 (0.0646) 51 1.36 (0.0535) 66 1.66 (0.0654) 52 1.38 (0.0543) 67 1.68 (0.0661) 53 1.40 (0.0551) 68 1.70 (0.0669) 54 1.42 (0.0559) 69 1.72 (0.0677) 55 1.44 (0.0567) 70 1.74 (0.0685) 56 1.46 (0.0575) 18 1.76 (0.0693) 57 1.48 (0.0583) 19 1.79 (0.0705) 58 1.50 (0.0591) 20 1.82 (0.0717) 59 1.52 (0.0598) 21 1.85 (0.0728) 60 1.54 (0.0606) 22 1.88 (0.0740) 61 1.56 (0.0614) – – HINT: As a rank of shim thickness is increased (0.020 mm) the preload of approx. 1.1 N·m (11.2 kgf·cm, 9.7 in.·lbf) is increased accordingly. 12. REMOVE 13 BOLTS, SEPARATE MG1 ASSEMBLY AND MG2 ASSEMBLY 13. (a) D09861 2001 PRIUS (RM778U) ADJUST SHIM Install the 2 bearing races and needle roller bearing to the MG1 assembly. HT–33 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY (b) Install the drive sprocket assembly to the MG1 assembly. (c) Install the input shaft assembly. (d) Install the 2 bearing races and needle roller bearing. (e) Install the planetary ring gear. (f) Install the ring gear flange. D09862 D09863 D09864 D09865 D09866 2001 PRIUS (RM778U) HT–34 HYBRID TRANSAXLE (g) Dimension A: – HYBRID TRANSAXLE ASSEMBLY Using a straight edge and vernier calipers, measure the dimension ”A” and ”B” correctly. Select a shim that will ensure that the value is within the specification. Shim thickness: Dimension ”B” – Dimension ”A” (h) Mark Thickness mm (in.) Mark Thickness mm (in.) 1 1.00 (0.0394) 7 2.20 (0.0866) 2 1.20 (0.0472) 8 2.40 (0.0945) 3 1.40 (0.0551) 9 2.60 (0.1024) 4 1.60 (0.0630) 10 2.80 (0.1102) 5 1.80 (0.0709) 11 3.00 (0.1181) 6 2.00 (0.0787) 12 3.20 (0.1260) A Dimension B: B D09929 (i) D09868 2001 PRIUS (RM778U) Install the counter drive gear assembly to the MG1 assembly. HT–35 HYBRID TRANSAXLE (j) Dimension A: – HYBRID TRANSAXLE ASSEMBLY Using a straight edge and vernier calipers, measure the dimension ”A” and ”B” correctly. Select a shim thickness is surely within the specified range. Shim thickness: Dimension ”B” – Dimension ”A” (k) Mark Thickness mm (in.) Mark Thickness mm (in.) A 1.35 (0.0531) G 1.65 (0.0650) B 1.40 (0.0551) H 1.70 (0.0669) C 1.45 (0.0571) J 1.75 (0.0689) D 1.50 (0.0591) K 1.80 (0.0709) E 1.55 (0.0610) L 1.85 (0.0728) F 1.60 (0.0630) – – A Dimension B: B D09930 14. (a) D09871 2001 PRIUS (RM778U) INSTALL INPUT SHAFT ASSEMBLY TO MG2 ASSEMBLY Install the shim selected in step 13 (h). HT–36 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY (b) Install the ring gear flange. (c) Install the 2 races and thrust bearing. HINT: Apply ATF to the thrust bearing. D09872 (d) Install the planetary ring gear. (e) Install the input shaft assembly. 15. INSTALL COUNTER DRIVE GEAR ASSEMBLY, CHAIN AND DRIVE SPROCKET ASSEMBLY Install the shim selected in step 13 (k). D09873 D09874 (a) D09875 (b) Install the counter drive gear assembly and chain at the same time. NOTICE: Install the chain with the mark plate facing up. Mark Plate D09876 2001 PRIUS (RM778U) HT–37 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY (c) Put the chain on the drive sprocket and install them. HINT: Apply ATF to the drive sprocket needle roller bearing. D09877 (d) Install the 2 bearing races and needle roller bearing. HINT: Apply ATF to the thrust bearing. D09878 16. (a) INSTALL PARKING LOCK PAWL TO MG1 ASSEMBLY Install the lock sleeve. (b) Install the cam guide sleeve to the sleeve bracket. (c) Install the cam guide sleeve, sleeve bracket, torsion spring and 2 bolts. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) D09879 D09742 D09931 2001 PRIUS (RM778U) HT–38 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY (d) (e) Install the parking lock pawl Using a screw driver, fit the torsion spring into a cut–out of the parking lock pawl. (f) Install the parking lock pawl shaft, lock clamp and bolt. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) 17. (a) INSTALL OIL PAN (MG2 side) Install a new O–ring to the oil strainer. (b) Install the bolt and oil strainer. Torque: 5.5 N·m (56 kgf·cm, 49 in.·lbf) (c) Install the magnet to the oil pan. D09880 D09739 D09883 D09707 D09884 2001 PRIUS (RM778U) HT–39 HYBRID TRANSAXLE (d) (e) (f) – HYBRID TRANSAXLE ASSEMBLY Apply liquid sealer to 2 or 3 threads of the bolt end. Sealant: Part No. 08833–00080, THREE BOND 2430, LOCTITE 204 or equivalent Install a new gasket and the oil pan with the 12 bolts. Torque: 7.6 N·m (77 kgf·cm, 67 in.·lbf) Install a new gasket and drain plug. Torque: 49 N·m (498 kgf·cm, 36 ft·lbf) D09706 18. (a) FIPG (b) INSTALL MG1 ASSEMBLY TO MG2 ASSEMBLY Apply FIPG to the MG2 assembly as shown in the illustration. FIPG: Part No. 08826 – 00090, THREE BOND 1281 or equivalent Install the MG1 to the MG2 (See page HT–26). D09886 NOTICE: When putting MG2 and MG1 together, assemble them so that the parking rod is inserted into the cam guide sleeve. D09885 (c) (d) Apply liquid sealer to 2 or 3 threads of the bolt end. Sealant: Part No. 08833 – 00080, THREE BOND 1344, LOCTITE 242 or equivalent Install the 21 bolts. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) D09695 19. (a) SST HINT: Drive in the oil seal unit SST comes into contact with the case. (b) Coat the lip of the oil seal with MP grease. 1 – 1.5 mm (0.039 – 0.059 in.) D09938 2001 PRIUS (RM778U) INSTALL OIL SEAL OF INPUT SHAFT (MG1 side) Using SST and a hammer, install a new oil seal. SST 09388–40010 Oil seal depth: 1 – 1.5 mm (0.039 – 0.059 in.) HT–40 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY 20. SET HYBRID TRANSAXLE ASSEMBLY Set the hybrid transaxle assembly as shown in the illustration. D09923 21. (a) (b) REASSEMBLE PARKING LOCK SHAFT ASSEMBLY Install the parking lock lever No. 3 to the parking lock shaft. Using a pin punch and a hammer, drive in the pin. D09720 (c) (d) (e) Turn the spacer and the lever shaft to align the small hole in the spacer with the staking position mark on the lever shaft. Using a pin punch, stake the spacer through the small hole. Check that the spacer does not turn. D08186 22. (b) (a) (b) (c) INSTALL PARKING LOCK SHAFT ASSEMBLY AND WASHER Apply ATF to the parking lock shaft. Apply MP grease to the parking lock lever No. 3. Install the washer to the parking lock shaft assembly. 23. INSTALL PARKING LOCK SHAFT ASSEMBLY (a) D09718 D09717 2001 PRIUS (RM778U) HT–41 HYBRID TRANSAXLE (a) (b) (c) SST D09887 (d) FIPG D09888 2001 PRIUS (RM778U) – HYBRID TRANSAXLE ASSEMBLY Using SST and a hammer, install a new oil seal to the parking shaft cover. SST 09950–60010 (09951–00230), 09950–70010 (09951–07100) Coat the lip of the oil seal with MP grease. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the parking shaft cover and MG2 case.
Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
Thoroughly clean all components to remove all the loose material.
Using a non–reusable solvent, clean both sealing surfaces. Apply FIPG to the parking shaft cover as shown in the illustration. FIPG: Part No. 08826 – 00090, THREE BOND 1281 or equivalent
Install a nozzle that has been cut to a 1.5 mm (0.06 in.) opening.
Parts must be assembled within 10 minutes after application. Otherwise the material must be removed and reapplied.
Remove the nozzle from the tube and reinstall the cap. HT–42 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY (e) D09715 FIPG Install the 5 bolts and parking shaft cover. Torque: 13 N·m (130 kgf·cm, 10 ft·lbf) NOTICE: When installing the cover, be careful not to damage the lip of the oil seal. 24. INSTALL MOTOR WATER JACKET COVER (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the motor water jacket cover and MG2 case.
Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
Thoroughly clean all components to remove all the loose material.
Using a non–reusable solvent, clean both sealing surfaces. (b) Apply FIPG to the motor water jacket cover as shown in the illustration. FIPG: Part No. 08826–00080 or equivalent
Install a nozzle that has been cut to a 1.5 mm (0.06 in.) opening.
Parts must be assembled within 10 minutes after application. Otherwise the material must be removed and reapplied.
Remove the nozzle from the tube and reinstall the cap. (c) Apply liquid sealer to 2 or 3 threads of the bolt end. Sealant: Part No. 08833 – 00080, THREE BOND 1344, LOCTITE 242 or equivalent Install the motor water jacket cover with the 6 bolts. Torque: 5.5 N·m (56 kgf·cm, 49 in.·lbf) D09889 (d) D09714 2001 PRIUS (RM778U) HT–43 HYBRID TRANSAXLE 25. (a) (b) – HYBRID TRANSAXLE ASSEMBLY INSTALL HOUSING TUBE Apply liquid sealer to 2 or 3 threads of the housing tube end. Sealant: Part No. 08833 – 00080, THREE BOND 1344, LOCTITE 242 or equivalent Install the housing tube. Torque: 15 N·m (152 kgf·cm, 11 ft·lbf) D09735 26. (a) (b) D09713 (c) FIPG D09890 2001 PRIUS (RM778U) INSTALL PARKING COVER Install the detent spring and detent spring cover with the bolt. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the parking cover and MG2 case.
Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
Thoroughly clean all components to remove all the loose material.
Using a non–reusable solvent, clean both sealing surfaces. Apply seal packing to the parking cover as shown in the illustration. FIPG: Part No. 08826 – 00090, THREE BOND 1281 or equivalent
Install a nozzle that has been cut to a 1.5 mm (0.06 in.) opening.
Parts must be assembled within 10 minutes after application. Otherwise the material must be removed and reapplied.
Remove the nozzle from the tube and reinstall the cap. HT–44 HYBRID TRANSAXLE – HYBRID TRANSAXLE ASSEMBLY (d) Install the parking cover with the 6 bolts. Torque: 5.5 N·m (56 kgf·cm, 49 in.·lbf) 27. (a) (b) INSTALL OIL PUMP Apply ATF to individual sliding parts. Install the oil pump drive shaft. (c) Install the oil pump driven rotor and drive rotor. (d) Install a new O–ring without twisting it.. (e) Apply liquid sealer to 2 or 3 threads of the bolt end. Sealant: Part No. 08833 – 00080, THREE BOND 1344, LOCTITE 242 or equivalent Install the oil pump cover with the 5 bolts. Torque: 5.5 N·m (56 kgf·cm, 49 in.·lbf) D09712 D09725 D09724 O–Ring D09723 (f) D09722 2001 PRIUS (RM778U) HT–45 HYBRID TRANSAXLE (g) (h) – HYBRID TRANSAXLE ASSEMBLY Install a new O–ring to the plug. Install the plug. Torque: 7.35 N·m (75 kgf·cm, 65 in.·lbf) D09721 28. INSTALL WIRING HARNESS CONNECTOR (MG2 side) Install the 2 wiring harness connectors with the 2 bolts. Torque: 5.5 N·m (56 kgf·cm, 49 in.·lbf) D09710 29. INSTALL WIRING HARNESS CONNECTOR (MG1 side) Install the wiring harness connector with the bolt. Torque: 5.5 N·m (56 kgf·cm, 49 in.·lbf) D09733 30. (a) (b) INSTALL 4 WATER JACKET UNIONS Apply liquid sealer to 2 or 3 threads of the union end. Sealant: Part No. 08833 – 00080, THREE BOND 1344, LOCTITE 242 or equivalent Install the 4 water jacket unions. Torque: 50 N·m (510 kgf·cm, 37 ft·lbf) D09895 31. (a) D09932 2001 PRIUS (RM778U) INSTALL HIGH–VOLTAGE CABLE Install the high–voltage cable with the 3 bolts. Torque: 18 N·m (183 kgf·cm, 13 ft·lbf) HT–46 HYBRID TRANSAXLE (b) (c) (d) D09933 Apply liquid sealer to 2 or 3 threads of the bolt end. Sealant: Part No. 08833 – 00080, THREE BOND 1344, LOCTITE 242 or equivalent Install the 3 bolts. Torque: 5.5 N·m (56 kgf·cm, 49 in.·lbf) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the power cable cover and MG1 case.
Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
Thoroughly clean all components to remove all the loose material.
Using a non–reusable solvent, clean both sealing surfaces. Apply FIPG to the power cable cover as shown in the illustration. FIPG: Part No. 08826 –00090, THREE BOND 1281 or equivalent
Install the nozzle that has been cut to a 1.5 mm (0.06 in) opening.
Parts must be assembled within 10 minutes after application. Otherwise the material must be removed and reapplied.
Remove the nozzle from the tube and reinstall the cap. (f) Install the power cable cover with the 4 bolts. Torque: 4.8 N·m (48 kgf·cm, 42 in.·lbf) D09891 2001 PRIUS (RM778U) HYBRID TRANSAXLE ASSEMBLY (e) FIPG D09731 – HT–47 HYBRID TRANSAXLE 32. (a) (b) D09709 2001 PRIUS (RM778U) – HYBRID TRANSAXLE ASSEMBLY INSTALL MOUNTING BRACKET Apply liquid sealer to 2 or 3 threads of the bolt end. Sealant: Part No. 08833 – 00070, THREE BOND 1324 or equivalent Install the mounting bracket with the 3 bolts. Torque: 52 N·m (530 kgf·cm, 38 ft·lbf) HT–54 HYBRID TRANSAXLE – SHIFT LOCK SYSTEM HT00J–02 INSPECTION 1. (a) (b) (c) INSPECT SHIFT POSITION SENSOR Remove the steering column upper cover and lower cover. Disconnect the shift position sensor connector. Check continuity between terminals shown below when the shift lever is moved to each position Shift Position Terminal No. to continuity Terminal No. to continuity P 1–2 3–8–9 R 1–4 3–8–9 N 1–5 3–8–9 D 1–6 3–8–9 B 1–7 3–8–9 D09790 (d) (e) 2001 PRIUS (RM778U) Connect the shift position sensor connector. Install the steering column upper cover and lower cover. HT–55 HYBRID TRANSAXLE B A IG SLS+ ACC P1 – SHIFT LOCK SYSTEM 2. INSPECT SHIFT LOCK CONTROL ECU Using a voltmeter, measure the voltage at each terminal. HINT: Do not disconnect the ECU connector. P P2 SLS– STP E KLS+ D09785 Terminal A, 1 – A, 5 (ACC – E) Measuring Condition Voltage (V) Ignition switch ACC 10 – 14 Ignition switch ON 10 – 14 A, 6 – A, 5 (STP – E) Depressing brake pedal 10 – 14 A, 4 – A, 5 (KLS+ – E) 5. Ignition switch ACC and P position 6. Ignition switch ACC and except P position 7. Ignition switch ACC and except P position (After approx. 1 second) 0 7.5 – 11 6 – 9.5 1. Ignition switch ON and P position 2. Depress brake pedal 3. Except P position 0 8 – 13.5 0 B, 2 – B, 4 (P1 – P) 1. Ignition switch ON, P position and depress brake pedal 2. Shift except P position under conditions above 0 9 – 13.5 B, 6 – B, 4 (P2 – P) 1. Ignition switch ACC, P position 2. Shift except P position under conditions above 9 – 13.5 0 A, 3 – A, 5 (IG – E) B, 1 – B, 5 (SLS+ – SLS–) 3. (a) (b) INSPECT SHIFT LOCK SOLENOID Disconnect the solenoid connector. Using an ohmmeter, measure the resistance between terminals. Standard resistance: 29 – 35 Ω If the resistance value is not as specified, replace the solenoid. D09783 (c) Apply battery positive voltage between terminals. Check the operation. If the solenoid does not operate, replace the solenoid noise can be heard from the solenoid. D09784 2001 PRIUS (RM778U) HT–56 HYBRID TRANSAXLE – SHIFT LOCK SYSTEM 4. (a) (b) INSPECT KEY INTERLOCK SOLENOID Disconnect the solenoid connector. Using an ohmmeter, measure the resistance between terminals 3 and 4. Standard resistance: 12.5 – 16.5 Ω If the resistance value is not as specified, replace the solenoid. I04108 (c) Apply battery positive voltage between the terminals 3 and 4. Check that an operation sound can be heard from the solenoid. If the solenoid does not operate, replace the solenoid. Q07191 B SLS+ 5. INSPECT SHIFT LOCK CONTROL SWITCH Check that there is continuity between terminals. A IG ACC P1 P P2 SLS– STP E KLS+ D09785 2001 PRIUS (RM778U) Shift position Tester connection Standard P position A, 5 – B, 2 (E – P1) Continuity P position (Pull the shift lever toward you) A, 5 – B, 2 (E – P1) A, 5 – B, 6 (E – P2) Continuity R, N, D, 2, L position A, 5 – B, 6 (E – P2) Continuity If continuity is not identified, replace the switch. HT–64 HYBRID TRANSAXLE – DIFFERENTIAL CASE HT00R–02 REASSEMBLY 1. (a) (b) ASSEMBLE DIFFERENTIAL CASE Coat the 2 side gear thrust washers and 2 pinion thrust washers with ATF. Install the 2 side gears, 2 pinions and 4 thrust washers to the case. D09770 (c) AT2799 Check the side gear backlash. Measure the side gear backlash while pushing one pinion gear toward the case. Standard backlash: 0.05 – 0.20 mm (0.0020 – 0.0079 in.) Referring to the table below, select thrust washers which backlash is surely within the specified range. Select washers of the same size for both sides. Thrust washer thickness Thickness Thickness 0.95 mm (0.0374 in.) 1.10 mm (0.0433 in.) 1.00 mm (0.0394 in.) 1.15 mm (0.0453 in.) 1.05 mm (0.0414 in.) 1.20 mm (0.0472 in.) If the backlash is not within the specified range, install a thrust washer of a different thickness. (d) (e) Using a pin punch and a hammer, install the straight pin. Stake the differential case. D09771 2. INSTALL 2 TAPERED ROLLER BEARINGS CAUTION: A: The one which has bigger rollers (The number of rollers is 22.) B: The one which has smaller rollers (The number of rollers is 24.) A B D09772 2001 PRIUS (RM778U) HT–65 HYBRID TRANSAXLE – DIFFERENTIAL CASE (a) Using SST and a press, press in the tapered roller bearing RH. (Bearing B) SST 09710–22021 (09710–01031), 09950–70010 (09951–07100) (b) Using SST and a press, press in the tapered roller bearing LH. (Bearing A) SST 09710–22021 (09710–01031), 09950–70010 (09951–07100) SST D09773 SST D09774 2001 PRIUS (RM778U) SA–2 SUSPENSION AND AXLE – TIRE AND WHEEL TIRE AND WHEEL SA0CC–10 INSPECTION 1. INSPECT TIRE (a) Check the tires for wear and proper inflation pressure. Cold tire inflation pressure: (Tire size: P175/65R14 84S) Front 240 kPa (2.4 (b) Rear kgf/cm2, 35 psi) 230 kPa (2.3 kgf/cm2, 33 psi) Using a dial indicator, check the tire runout. Tire runout: 1.0 mm (0.039 in.) or less R03031 2. ROTATING TIRES HINT: See the illustration for where to rotate each tire. Front R15157 3. (a) (b) INSPECT WHEEL BALANCE Check and adjust the Off–the–car balance. If necessary, check and adjust the On–the–car balance. Imbalance after adjustment: 8.0 g (0.018 lb) or less R07928 Backlash: 4. (a) Deviation: R14731 CHECK WHEEL BEARING LOOSENESS Using a dial indicator, check the backlash near the center of the axle hub. Maximum: 0.05 mm (0.0020 in.) If the backlash exceeds the maximum, replace the bearing. (b) Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt. Maximum: 0.07 mm (0.0028 in.) If the deviation exceeds the maximum, replace the axle hub. 2001 PRIUS (RM778U) Author: Date: 1452 SA–3 SUSPENSION AND AXLE 5. 6. 7. 8.


– TIRE AND WHEEL CHECK FRONT SUSPENSION FOR LOOSENESS CHECK STEERING LINKAGE FOR LOOSENESS CHECK BALL JOINT FOR LOOSENESS CHECK SHOCK ABSORBER WORKS PROPERLY Check if oil leaks Check mounting bushings for wear Bounce front and rear of the vehicle 2001 PRIUS (RM778U) Author: Date: 1453 SA–4 SUSPENSION AND AXLE – FRONT WHEEL ALIGNMENT FRONT WHEEL ALIGNMENT Front: SA1CK–11 INSPECTION 1. MEASURE VEHICLE HEIGHT Vehicle height: Tire size Front*1 mm (in.) 175/65R14 191 (7.52) Rear*2 mm (in.) 239 (9.41) *1: Front measuring point Measure the distance from the ground to the head center of the front side lower suspension arm mounting bolt. *2: Rear measuring point Measure the distance from the ground to the center of the rear axle beam mounting bolt. NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specified value. If the vehicle height is not the specified value, try to adjust it by pushing down on or lifting the body. Rear: F11573 2. Gauge Alignment Tester INSTALL CAMBER–CASTER–KINGPIN GAUGE OR POSITION VEHICLE ON WHEEL ALIGNMENT TESTER Follow the specific instructions of the equipment manufacturer. 3. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION Camber, caster and steering axis inclination: Right–left error –0°26’ ± 45’ (–0.43° ± 0.75°) 45’ (0.75°) or less Right–left error 1°02’ ± 45’ (1.03° ± 0.75°) 45’ (0.75°) or less Right–left error 9°52’ ± 45’ (9.87° ± 0.75°) 45’ (0.75°) or less Camber Z03382 Caster Steering axis inclination If the caster and steering axis inclination are not within the specified values, after the camber has been correctly adjusted, recheck the suspension parts for damaged and/or worn out parts. 4. ADJUST CAMBER NOTICE: After the camber has been adjusted, inspect the toe–in. (a) Remove the front wheel. (b) Remove the 2 nuts on the lower side of the shock absorber. If reusing the bolts and/or nuts, coat the threads of nuts with engine oil. (c) Clean the installation surfaces of the shock absorber and the steering knuckle. (d) Temporarily install the 2 nuts. F07339 2001 PRIUS (RM778U) Author: Date: 1454 SA–5 SUSPENSION AND AXLE (e) 
(f) (g) (h) HINT: : Use with adjusting bolt – FRONT WHEEL ALIGNMENT Adjust the camber by pushing or pulling the lower side of the shock absorber in the direction in which the camber adjustment is required. Tighten the nuts. Torque: 153 N·m (1,560 kgf·cm, 113 ft·lbf) Install the front wheel. Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) Check the camber.
Try to adjust the camber to the center of the specified value.
Adjusting value for the set bolts is 6’ – 30’ (0.1° – 0.5°). If the camber is not within the specified value, using the following table, estimate how much additional camber adjustment will be required, and select the camber adjusting bolt. NOTICE: Tighten the adjusting bolt with a washer and a new nut. 1 2 F07326 Adjusting Bolt Set Bolt Bolt Adjusting Value 90105–15001 90105–15004 90105–15005 90105–15006 1 Dot 3 Dots 1 2 1 2 2 Dots 1 2 1 2 –1°30’ – –1°15’ –1°15’ – –1°00’ –1°00’ – –45’ –45’ – –30’ –30’ – –15’ –15’ – 0’ 0’ – 15’ 15’ – 30’ 30’ – 45’ 45’ – 1°00’ 1°00’ – 1°15’ 1°15’ – 1°30’ F12938 (i) Do the steps mentioned above again. At step (b), replace 1 or 2 selected bolts. HINT: When replacing the 2 bolts, replace 1 bolt for each time. 2001 PRIUS (RM778U) Author: Date: 1455 SA–6 SUSPENSION AND AXLE A – FRONT WHEEL ALIGNMENT 5. INSPECT TOE–IN Toe–in: B D Toe–in (total) Front A + B: 0°06’ ± 12’ (0.1° ± 0.2°) C – D: 1 ± 2 mm (0.04 ± 0.08 in.) If the toe–in is not within the specified value, adjust it at the rack ends. 6. ADJUST TOE–IN (a) Remove the rack boot set clips. C SA3213 (b) (c) Loosen the tie rod end lock nuts. Turn the right and left rack ends by an equal amount to adjust the toe–in. HINT: Try to adjust the toe–in to the center of the specified value. F11574 (d) (e) Make sure that the lengths of the right and left rack ends are the same. Rack end length difference: 1.5 mm (0.059 in.) or less Torque the tie rod end lock nuts. Torque: 74 N·m (750 kgf·cm, 55 ft·lbf) Place the boots on the seats and install the clips. (f) HINT: Make sure that the boots are not twisted. F11575 A B B 7. INSPECT WHEEL ANGLE Turn the steering wheel fully and measure the turning angle. Wheel turning angle: A Front Inside wheel 42°42’ ± 2° (42.70° ± 2°) Outside wheel: Reference 35°54’ (35.90°) If the right and left inside wheel angles differ from the specified value, check the right and left rack end lengths. A: Inside B: Outside SA0028 2001 PRIUS (RM778U) Author: Date: 1456 SA–9 SUSPENSION AND AXLE – FRONT AXLE HUB SA1ZR–01 REMOVAL 1. REMOVE FRONT WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 2. CHECK BEARING BACKLASH AND AXLE HUB DEVIATION Remove the 2 bolts, brake caliper and disc. Support the brake caliper securely. (a) (b) F08617 Backlash: (c) Deviation: R14731 SST F12940 2001 PRIUS (RM778U) Using a dial indicator, check the backlash near the center of the axle hub. Maximum: 0.05 mm (0.0020 in.) If the backlash exceeds the maximum, replace the bearing. (d) Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt. Maximum: 0.07 mm (0.0028 in.) If the deviation exceeds the maximum, replace the axle hub. (e) Install the disc, 2 bolts and brake caliper. Torque: 107 N·m (1,090 kgf·cm, 79 ft·lbf) 3. REMOVE DRIVE SHAFT LOCK NUT (a) Using SST and a hammer, unstake the staked part of the lock nut. SST 09930–00010 (b) While applying the brakes, remove the nut. Torque: 216 N·m (2,200 kgf·cm, 159 ft·lbf) (c) Remove the brake caliper and disc. (d) Support the brake caliper securely. 4. REMOVE ABS SPEED SENSOR Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf) SA–10 SUSPENSION AND AXLE 5. F12941 – FRONT AXLE HUB LOOSEN 2 NUTS ON LOWER SIDE OF SHOCK ABSORBER Torque: 153 N·m (1,560 kgf·cm, 113 ft·lbf) HINT: Do not remove the 2 bolts and nuts. 6. DISCONNECT TIE ROD END FROM STEERING KNUCKLE (a) Remove the cotter pin and nut. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) HINT: At the time of installation, if the holes for a new cotter pin are not aligned, tighten the nut further up to 60°. (b) Using SST, disconnect the tie rod end from the steering knuckle. SST 09628–62011 SST F11576 7. DISCONNECT LOWER SUSPENSION ARM FROM LOWER BALL JOINT Remove the 2 nuts and bolt. Torque: 142 N·m (1,450 kgf·cm, 105 ft·lbf) F11617 8. (a) F12941 2001 PRIUS (RM778U) REMOVE STEERING KNUCKLE WITH AXLE HUB Remove the 2 bolts and nuts on the lower side of the shock absorber. HINT: At the time of installation, coat the nut’s thread with engine oil. (b) Remove the steering knuckle with the axle hub. NOTICE: Be careful not to damage the boot and ABS speed sensor rotor. SA–11 SUSPENSION AND AXLE – FRONT AXLE HUB SA07D–07 DISASSEMBLY SST 1. (a) REMOVE LOWER BALL JOINT Remove the cotter pin and nut. (b) Using SST, remove the lower ball joint. SST 09628–62011 2. (a) REMOVE AXLE HUB Using SST, remove the axle hub. SST 09520–00031 (09520–00040, 09521–00010, 09521–00020) F11577 SST F11578 (b) SST R14739 2001 PRIUS (RM778U) Using SST, remove the inner race (outside) from the axle hub. SST 09950–40011 (09951–04020, 09952–04010, 09953–04020, 09954–04010, 09955–04011, 09957–04010, 09958–04011), 09950–60010 (09951–00370) 3. REMOVE DUST COVER Using a torx socket (T30), remove the 3 bolts and dust cover. 4. REMOVE BEARING FROM STEERING KNUCKLE (a) Using snap ring pliers, remove the snap ring. (b) Place the inner race on the outside of the bearing. SA–12 SUSPENSION AND AXLE (c) SST SST F11579 2001 PRIUS (RM778U) – FRONT AXLE HUB Using SST and a press, remove the bearing. SST 09527–17011, 09950–60010 (09951–00650), 09950–70010 (09951–07150) SA–17 SUSPENSION AND AXLE – FRONT DRIVE SHAFT SA20B–01 REMOVAL SST FA1535 NOTICE:
The hub bearing could be damaged if it is subjected to the vehicle weight, such as when moving the vehicle with the drive shaft removed. Therefore, if it is absolutely necessary to place the vehicle weight on the hub bearing, first support it with the SST. SST 09608–16042 (09608–02021, 09608–02041)
After disconnecting the drive shaft from the axle hub, work carefully so as not to damage the ABS speed sensor rotor serrations on the drive shaft. 1. REMOVE FRONT WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 2. REMOVE ENGINE UNDER COVER 3. DRAIN ATF 4. (a) (b) 5. SST F12940 (a) REMOVE DRIVE SHAFT LOCK NUT Using SST and a hammer, unstake the staked part of the lock nut. SST 09930–00010 While applying the brakes, remove the nut. Torque: 216 N·m (2,200 kgf·cm, 159 ft·lbf) DISCONNECT TIE ROD END FROM STEERING KNUCKLE Remove the cotter pin and nut. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) HINT: At the time of installation, if the holes for a new cotter pin are not aligned, tighten the nut further up to 60°. (b) SST F11576 2001 PRIUS (RM778U) Using SST, disconnect the tie rod end from the steering knuckle. SST 09628–62011 SA–18 SUSPENSION AND AXLE – FRONT DRIVE SHAFT 6. DISCONNECT LOWER BALL JOINT FROM LOWER SUSPENSION ARM Remove the 2 nuts and bolt. Torque: 142 N·m (1,450 kgf·cm, 105 ft·lbf) F11617 7. DISCONNECT DRIVE SHAFT FROM AXLE HUB Using a plastic hammer, disconnect the drive shaft from the axle hub. NOTICE: Be careful not to damage the boot and ABS speed sensor rotor. F13342 8. (a) SST 2001 PRIUS (RM778U) F11614 REMOVE DRIVE SHAFT Using SST, remove the drive shaft. SST 09520–01010, 09520–24010 (09520–32040) NOTICE: Be careful not to damage the oil seal and dust cover. HINT: At the time of installation, please refer to the following items.
Apply gear oil to the inboard joint shaft and differential case sliding surfaces.
Before installing the drive shaft, set the snap ring with its opening side facing downward.
Whether inboard joint shaft is in contact with pinion shaft or not can be known from the sound or feeling.
After installation, check that there is 2 – 3 mm (0.08 – 0.12 in.) of play in the axial direction.
After installation, check that the drive shaft cannot be removed by hand. (b) Using a screwdriver, remove the snap ring from the inboard joint shaft. SA–19 SUSPENSION AND AXLE – FRONT DRIVE SHAFT SA20C–01 DISASSEMBLY 1. (a) (b) (c) N00191 (d) (e) 2. (a) Type A: (b) CHECK DRIVE SHAFT Check to see that there is no remarkable play in the outboard joint. Check to see that the inboard joint slides smoothly in the thrust direction. Check to see that there is no remarkable play in the radial direction of the inboard joint. Check the boots for damage. Check the shape of the boot clamp. REMOVE INBOARD JOINT SHAFT Using a screwdriver, disclamp the 2 inboard joint boot clamps. Slide the inboard joint boot toward the outboard joint. Type B: F12937 (c) Place matchmarks on the inboard joint shaft and tripod. NOTICE: Do not punch the marks. (d) Remove the inboard joint shaft from the outboard joint shaft. 3. REMOVE TRIPOD (a) Using a snap ring expander, remove the snap ring. Matchmarks R11817 Matchmarks N00194 2001 PRIUS (RM778U) (b) Place matchmarks on the outboard joint shaft and tripod. NOTICE: Do not punch the marks. (c) Using a brass bar and hammer, tap out the tripod from the outboard joint shaft. NOTICE: Do not tap the roller. 4. REMOVE INBOARD JOINT BOOT AND 2 CLAMPS 5. RH drive shaft: REMOVE DYNAMIC DAMPER (a) Type A clamp: Using a screwdriver, disclamp the dynamic damper clamp and remove it. SA–20 SUSPENSION AND AXLE (b) (c) 6. (a) A B – FRONT DRIVE SHAFT Type B clamp: Using pliers, pinch the claw A and B to compress the dynamic damper clamp and remove it. Remove the dynamic damper. REMOVE OUTBOARD JOINT BOOT Type A clamp: Using a screwdriver disclamp the 2 outboard joint boot clamps. F12935 (b) F13343 SST R09716 2001 PRIUS (RM778U) Type B clamp: Using a side cutter, cut the 2 outboard joint boot clamps and remove it. NOTICE: Cut the part shown by the arrow so that the boot will not be damaged. (c) Remove the outboard joint boot from the outboard joint shaft. NOTICE: Do not disassemble the outboard joint. 7. REMOVE DUST COVER Using SST and a press, remove the dust cover from the inboard joint shaft. SST 09950–00020 SA–21 SUSPENSION AND AXLE – FRONT DRIVE SHAFT SA20D–01 REASSEMBLY 1. INSTALL DUST COVER Using a press, install a new dust cover to the inboard joint shaft. SA1459 2. Vinyl Tape W01994 2001 PRIUS (RM778U) TEMPORARILY INSTALL BOOTS, CLAMPS AND DYNAMIC DAMPER (RH DRIVE SHAFT) HINT: Before installing the boots (and dynamic damper), wrap the spline of the outboard joint shaft with vinyl tape to prevent them from being damaged. (a) Place either 2 new A or B type boot clamps on a new outboard joint boot and install them to the outboard joint shaft. (b) RH drive shaft: Place either a new A or B type clamp on the dynamic damper and install them to the outboard joint shaft. HINT: For B type only, the used clamp can be employed. (c) Place 2 new clamps on a new inboard joint boot and install them to the outboard joint shaft. 3. INSTALL TRIPOD (a) Place the beveled side of the tripod axial spline toward the outboard joint. (b) Align the matchmarks placed before removal. (c) Using a brass bar and hammer, tap in the tripod to the outboard joint shaft. NOTICE: Do not tap the roller. (d) Using a snap ring expander, install a new snap ring. 4. INSTALL BOOT TO OUTBOARD JOINT Before assembling the boot, pack the outboard joint and boot with grease in the boot kit. Grease capacity: (Color = Yellow ocher) 110 – 120 g (3.9 – 4.2 oz.) 5. INSTALL INBOARD JOINT SHAFT TO OUTBOARD JOINT SHAFT (a) Pack the inboard joint and boot with grease in the boot kit. Grease capacity: (Color = Yellow ocher) 180 – 190 g (6.3 – 6.7 oz.) (b) Align the matchmarks placed before removal. (c) Install the inboard joint shaft to the outboard joint shaft. (d) Temporarily install the boot to the inboard joint shaft. 6. ASSEMBLE BOOT CLAMPS TO BOTH BOOTS (a) Make sure that the 2 boots are on the shaft grooves. SA–22 SUSPENSION AND AXLE – FRONT DRIVE SHAFT (b) Make sure that the 2 boots are not stretched or contracted when the drive shaft is at standard length. Drive shaft standard length: RH LH RH 836.9 ± 5.0 mm (32.949 ± 0.197 in.) LH 579.9 ± 5.0 mm (22.831 ± 0.197 in.) (c) Bend the band and lock the 2 inboard joint boot clamps with a screwdriver. (d) (e) Install either A or B type boot clamp. Type A clamp: Bend the band and lock the 2 outboard joint boot clamps with a screwdriver. Z12938 Type A: Type B: F12937 (f) SST R10425 Type B clamp: Pinch the 2 outboard joint boot clamps. (1) Secure the 2 outboard joint boot clamps onto the boot. (2) Place SST onto the outboard joint large boot clamp. SST 09521–24010 (3) Tighten the SST so that the large clamp is pinched. NOTICE: Do not overtighten the SST. (4) Using SST, adjust the clearance of the large clamp. SST 09240–00020 Clearance: 0.8 mm (0.031 in.) or less (5) Employ the same manner to the outboard joint small boot clamp. SST R10426 7. (a) (b) (c) F11615 8. 2001 PRIUS (RM778U) RH drive shaft: ASSEMBLE DYNAMIC DAMPER CLAMP Set the distance, as described below. Distance: 500.1 ± 2.0 mm (19.689 ± 0.079 in.) Type A clamp: Bend the band and lock the dynamic damper clamp with a screwdriver. Type B clamp: Using pliers, compress the clamp and attach the claws. CHECK DRIVE SHAFT (See page SA–19) SA–29 SUSPENSION AND AXLE – FRONT SHOCK ABSORBER SA1P6–02 REASSEMBLY 1. 2. INSTALL LOWER INSULATOR ONTO SHOCK ABSORBER INSTALL SPRING BUMPER TO PISTON ROD 3. (a) SST F11581 INSTALL COIL SPRING Using SST, compress the coil spring. SST 09727–30021 (09727–00010, 09727–00021, 09727–00031) NOTICE: Do not use an impact wrench. It will damage the SST. (b) Install the coil spring to the shock absorber. HINT: Fit the lower end of the coil spring into the gap of the spring lower seat. (c) Install the upper insulator as shown in the illustration. Out F11582 (d) (e) Install the spring seat to the shock absorber with the ” ” mark facing to the outside of the vehicle. Install the dust seal and suspension support. F11583 (f) (g) SST F08624 2001 PRIUS (RM778U) Using SST to hold the suspension support, install a new nut. SST 09729–22031 Torque: 47 N·m (475 kgf·cm, 34 ft·lbf) Remove the SST. SST 09727–30021 (09727–00010, 09727–00021, 09727–00031) SA–30 SUSPENSION AND AXLE FRONT SHOCK ABSORBER (h) Apply MP grease No.2 into the suspension support. CAUTION: Do not touch grease on rubber surface of upper support. (i) Install the cap. MP Grease No.2 F11584 2001 PRIUS (RM778U) – SA–33 SUSPENSION AND AXLE – FRONT LOWER SUSPENSION ARM SA1ZW–01 REMOVAL 1. 2. 3. (a) REMOVE FRONT WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) REMOVE ENGINE UNDER COVER REMOVE LOWER SUSPENSION ARM Disconnect the RH and LH tie rod ends. (1) Remove the cotter pin and nut. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) (2) Using SST, disconnect the tie rod end from the steering knuckle. SST 09628–62011 (3) Employ the same manner described above to the other side. SST F11576 (b) F11616 Disconnect the RH and LH stabilizer bar links. (1) Remove the nut and disconnect the stabilizer bar link from the shock absorber. Torque: 74 N·m (755 kgf·cm, 55 ft·lbf) HINT: If the ball joint turns together with the nut, use a hexagon (5 mm) wrench to hold the stud. (2) Employ the same manner described above to the other side. (c) Disconnect the RH and LH lower suspension arms from the lower ball joints. (1) Remove the bolt and 2 nuts, and disconnect the lower suspension arm from the lower ball joint. Torque: 142 N·m (1,450 kgf·cm, 105 ft·lbf) (2) Employ the same manner described above to the other side. (d) Loosen the 2 lower suspension arm set bolts. Torque: 137 N·m (1,397 kgf·cm, 101 ft·lbf) F11617 HINT: At the time of installation, after stabilizing the suspension, torque the bolts. (e) Disconnect the sliding yoke (See page SR–6). (f) Support the suspension member with a transmission jack. F11586 2001 PRIUS (RM778U) SA–34 SUSPENSION AND AXLE – FRONT LOWER SUSPENSION ARM (g) Remove the bolt and nut, disconnect the torque rod from the suspension member. Torque: 100 N·m (1,150 kgf·cm, 83 ft·lbf) (h) Remove the 4 bolts and disconnect the suspension member from the body. Torque: Front side: 113 N·m (1,152 kgf·cm, 83 ft·lbf) Rear side: 157 N·m (1,600 kgf·cm, 116 ft·lbf) Remove the 2 lower suspension arm set bolts and disconnect the lower suspension arm from suspension member. F12936 (i) F12933 2001 PRIUS (RM778U) SA–51 SUSPENSION AND AXLE – REAR SHOCK ABSORBER SA1ZU–01 REMOVAL 1. 2. 3. (a) (b) (c) REMOVE REAR WHEELS Torque: 103 N·m (250 kgf·cm, 18 ft·lbf) REMOVE REAR SEAT (See page BO–83) DISCONNECT BRAKE LINES Using SST, disconnect the brake lines from the flexible hose. Use a container to catch brake fluid as it drains out. SST 09751–36011 Remove the clip. Employ the same manner described above to the other side. SST F11598 4. DISCONNECT ABS SPEED SENSOR WIRE HARNESS Remove the 4 nuts, and disconnect the ABS speed sensor wire harness from the axle beam. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) F11599 5. SUPPORT REAR AXLE BEAM AT RIGHT AND LEFT SIDES WITH JACKS 6. (a) REMOVE SHOCK ABSORBER Remove the 2 nuts and bolt. Torque: 80 N·m (816 kgf·cm, 59 ft·lbf) Wood F11593 F11618 2001 PRIUS (RM778U) SA–52 SUSPENSION AND AXLE (b) F11619 2001 PRIUS (RM778U) – REAR SHOCK ABSORBER Remove the nut, washer and shock absorber. Torque: 80 N·m (816 kgf·cm, 59 ft·lbf) SA–60 SUSPENSION AND AXLE – REAR AXLE BEAM SA1ZV–01 REPLACEMENT 1. (a) (b) REMOVE TOE CONTROL LINK Remove the nut. Using a brass bar, remove the bolt. F11600 (c) Using a SST, remove the toe control link from axle beam. SST 09710–40010 (09711–40010, 09712–40010), 09727–30021 (09727–00010, 09727–00031) NOTICE:
Make sure that the arm inside of SST is contact with the toe control link at the position shown in the illustration.
Never use SST (09727 – 00030) SST F11601 HINT: The outer race of the toe control link is made of rubber and because of its elasticity, it is difficult to remove the link from the axle beam. So, tap the part indicated by the arrow with a plastic hammer when removing. SST F11602 2. (a) F11603 2001 PRIUS (RM778U) INSTALL TOE CONTROL LINK Using a SST, install a new toe control link. SST 09710–40010 (09711–40010, 09712–40010), 09727–30021 (09727–00010, 09727–00031) NOTICE:
Make sure that the arm inside of SST is contact with the frange of the toe control link.
Align the bolt holes of the toe control link and axle beam in the direction of press–fitting. When the bolt holes slip off the aligned position, press–fit a new toe control link again. HINT:
Until the outer race is fit into the axle beam, adjust the arm position of SST to set the toe control link upright to the axle beam.
When the toe control link is fully press–fit into the axle beam, the bolt holes are not aligned. SA–61 SUSPENSION AND AXLE – REAR AXLE BEAM (b) Using a extension bar and press, install a new bolt. NOTICE: Press in the bolt until the base of the bolt head is pressed tightly against the axle beam. (c) Install the a nut. F11604 2001 PRIUS (RM778U) BR–2 BRAKE – TROUBLESHOOTING TROUBLESHOOTING BR0PX–07 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Low pedal or spongy pedal Suspect Area See page 5. Fluid leaks for brake system 6. Air in brake system 7. Piston seals (Worn or damaged) DI–451 BR–4 BR–26 BR–32 BR–16 BR–42 8. Master cylinder (Faulty) 9. Hydraulic brake booster (Faulty) 1. 2. 3. 4. Brake drag Brake pedal freeplay (Minimum) Parking brake pedal travel (Out of adjustment) Parking brake wire (Sticking) Pad or lining (Cracked or distorted) 5. Piston (Stuck) 6. Piston (Frozen) 7. Tension or return spring (Faulty) 8. Hydraulic brake booster (Faulty) 1. Piston (Stuck) BR–26 BR–32 BR–23 BR–32 BR–26 BR–32 BR–26 BR–32 BR–23 BR–32 BR–42 2. Pad or lining (Cracked or distorted) 3. Piston (Frozen) Brake pull 4. Disc or drum (Scored) 5. Pad or lining (Cracked or distorted) 6. Hydraulic brake booster (Faulty) 1. Fluid leaks for brake system 2. Air in brake system 3. Pad or lining (Worn) DI–451 BR–4 BR–23 BR–32 BR–23 BR–32 BR–23 BR–32 BR–23 BR–32 BR–26 BR–32 BR–42 4. Pad or lining (Cracked or distorted) Hard pedal but brake inefficient BR–7 BR–9 – BR–23 BR–32 BR–26 BR–32 BR–26 BR–32 BR–32 BR–42 5. Pad or lining (Oily) 6. Pad or lining (Glazed) 7. Disc or drum (Scored) 8. Hydraulic brake booster (Faulty) 2001 PRIUS (RM778U) Author: Date: 1517 BR–3 BRAKE – TROUBLESHOOTING 1. Pad or lining (Cracked or distorted) 8. Tension or return spring (Faulty) 9. Anti–squeal shim (Damaged) 10.Shoe hold–down spring (Damaged) BR–23 BR–32 BR–26 BR–26 BR–32 BR–23 BR–26 BR–23 BR–32 BR–23 BR–32 BR–32 BR–23 BR–32 1. Brake fluid level 2. Hydraulic brake booster power supply system (Faulty) BR–41 Hydraulic brake booster power supply system (Faulty) BR–41 1. Anti–lock brake system (Faulty) 2. Hydraulic brake booster power supply system (Faulty) BR–41 2. Installation bolt (Loose) 3. Disc or drum (Scored) 4. Pad support plate (Loose) 5. Sliding pin (Worn) 6. Pad or lining (Dirty) Noise from brakes 7. Pad or lining (Glazed) Brake warning light lights up*1 (Parking brake pedal released) Brake warning light lights up and brake warning buzzer ABS warning light lights up*3 sounds*2 *1, *3: The light may stay on for about 60 seconds after the engine has been started. It is normal if it goes out after a while. *2, *3: Depressing the brake pedal repeatedly may turn on the warning light and buzzer. It is normal if the light goes out and the buzzer stops sounding after a few seconds. 2001 PRIUS (RM778U) Author: Date: 1518 BR–4 BRAKE – BRAKE FLUID BRAKE FLUID BR1J6–01 BLEEDING HINT:
If any work is done on the brake system or if air in the brake lines is suspected, bleed the air from the system.
When bleeding, keep the amount of the fluid within the line of reservoir between Min. and Max. NOTICE:
Do not let brake fluid remain on painted surfaces. Wash it off immediately.
With the reservoir cap removed, when depressing the brake pedal, the fluid will spray. 1. FILL RESERVOIR WITH BRAKE FLUID Fluid: SAE J1703 or FMVSS NO. 116 DOT3 2. RELEASE PRESSURE FROM POWER SUPPLY SYSTEM HINT: If the hydraulic brake booster has been disassembled, disconnect the brake line from the hydraulic brake booster or if the reservoir becomes empty, bleed the hydraulic brake booster. (a) Turn the ignition switch OFF, depress the brake pedal more than 40 times. (b) Turn the ignition switch ON, check that the pump stops after 30 to 40 seconds. NOTICE: When the pump does not stop, repeat step (a) and (b) again. 3. BLEED AIR (a) Turning the ignition switch OFF, bleed the right and left front brake caliper. HINT: Perform air bleeding for each wheel, depress the brake pedal more than 20 times or more for each. (b) Turning the ignition switch ON, check that the pump motor stops. (c) Fully open the bleeder plug of the right or left rear brake cylinder and drain the fluid while depressing the brake pedal for 3 seconds. HINT:
Perform air bleeding for both wheels on the right or left side and then do the same on the other side.
It is not necessary to depress the pedal continuously, as brake fluid flows out by first depressing. (d) Release the brake pedal and wait until the pump motor stops. (e) Repeat step (c) and (d) 7 times or more. (f) Tighten the bleeder plug of the rear brake cylinder. Torque: 8.5 N·m (87 kgf·cm, 75 in.·lbf) (g) While depressing the brake pedal, let air out from the rear brake cylinder mentioned in (f). 2001 PRIUS (RM778U) Author: Date: 1519 BR–5 BRAKE – BRAKE FLUID HINT:



(h) (i) (j) (k) (l) (m) (n) Hold the brake pedal depressed, and it is not necessary to repeat depressing of the pedal. Do not continuously drain the fluid from the bleeder plug for more than 3 seconds. When closing the bleeder plug, wait until the pump motor stops if it is operated. Repeat the procedure until air is completely removed. Perform step (c) to (g) on the other rear brake cylinder. With the ignition switch ON, check that the pump motor is stopped. Fully the bleeder plug of the front left brake cylinder and drain the fluid while depressing the brake pedal for 3 seconds. Release the brake pedal and wait until the pump motor stops. Repeat step (j) and (k) 4 times. Tighten the bleeder plug of the front left brake cylinder. Torque: 8.5 N·m (87 kgf·cm, 75 in.·lbf) While depressing the brake pedal, let air out from the front left brake cylinder. HINT:



(o) TOYOTA Hand–held Tester DLC3 (p) Hold the brake pedal depressed, and it is not necessary to repeat depressing of the pedal. Do not continuously drain the fluid from the bleeder plug for more than 3 seconds. When closing the bleeder plug, wait until the pump motor stops if it is operated. Repeat the procedure until air is completely removed. Check that the pump motor is stopped. Connect TOYOTA hand–held tester. (1) Turn the ignition switch OFF, connect the TOYOTA hand–held tester to DLC3. (2) Turn the ignition switch ON, and select ”AIR BLEEDING” on the TOYOTA hand–held tester. HINT: Please refer to the TOYOTA hand–held tester operator’s manuT al for further details. (q) Holding the brake pedal depressed, turn SRRR solenoid F12396 ON with the TOYOTA hand–held tester. 2001 PRIUS (RM778U) Author: Date: 1520 BR–6 BRAKE – BRAKE FLUID HINT: Do not keep the solenoid activated for 2 seconds, or more. Allow an interval of 20 seconds, or more if activating it continuously. (r) Turn the SRRR solenoid OFF with the TOYOTA hand– held tester, and release the brake pedal. (s) Check that the pump motor stops after 20 seconds. (t) Repeat step (q) to (s) 3 times. (u) Turn the ignition switch OFF, and disconnect the TOYOTA hand–held tester from DLC3. (v) Clear the DTC (See page DI–353). HINT:
Diagnosis codes are erased with the shift lever in P range.
After erasing, turn the ignition switch OFF to protect ECU. 4. CHECK FLUID LEVEL IN RESERVOIR (a) With the ignition switch OFF, depress the brake pedal more than 40 times. (b) Remove the reservoir cap. Add brake fluid up to the ”MAX” line. Fluid: SAE J1703 or FMVSS NO. 116 DOT3 2001 PRIUS (RM778U) Author: Date: 1521 BR–10 BRAKE – PARKING BRAKE PEDAL BR1JA–01 COMPONENTS Cluster Finish Panel Passenger Air Bag Assembly Combination Meter No. 2 Side Defroster Nozzle Front Pillar Garnish Front Pillar Garnish No. 3 Register No. 1 Side Defroster Nozzle Hazard Warning Switch No. 1 Register Instrument Panel Finish Panel Upper Column Cover Steering Wheel Cluster Finish Panel Assembly Steering Wheel Pad Radio Tuner Opening Cover Spiral Cable Lower Column Cover 50 (510, 37) Glove Compartment Door Lower Finish Panel Hood Lock Release Lever Lower Center Cluster Finish Panel Cowl Side Trim Cowl Side Trim Front Door Scuff Plate Front Door Scuff Plate N·m (kgf·cm, ft·lbf) : Specified torque 2001 PRIUS (RM778U) F12629 BR–11 BRAKE – PARKING BRAKE PEDAL 14 (143, 10) Nut 13 (130, 9) Parking Brake Pedal Assembly Parking Brake Wire Clip Pedal Bracket Adjusting Nut Lock Nut 5.4 (55, 48 in.·lbf) Cushion Plate Return Spring
Bushing Parking Brake switch
Bushing 32 (327, 24) Pedal Pad Pedal Assembly N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Lithium soap base glycol grease 2001 PRIUS (RM778U) F12632 BR–16 BRAKE – BRAKE MASTER CYLINDER BRAKE MASTER CYLINDER BR1JF–01 COMPONENTS Wiper Arm 26 (270, 20) Cowl Top Ventilator Louver RH Cowl Top Ventilator Louver LH Hood to Cowl Top Seal Wiper Motor Cover Wiper Motor & Link Assembly Inverter Terminal Cover Outer Front Cowl Top Panel 7.4 (75, 64 in.·lbf) 8.0 (82, 71 in.·lbf) Engine Room R/B No. 2
Gasket 5.4 (55, 48 in.·lbf) 21 (214, 15) 8.0 (82, 71 in.·lbf) 21 (214, 15) MG 2 Lower Finish Panel 8.0 (82, 71 in.·lbf) 20 (204, 15) Converter and Inverter Assembly MG 1 Clip Reservoir Hose Circuit Breaker Sensor Hood Lock Release Lever Connector Cover Finish Panel Clip Front Door Scuff Plate Wave Washer Clip Reservoir Hose Cowl Side Trim Clevis Pin 15 (155, 11) 13 (130, 9) Master Cylinder N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Lithium soap base glycol grease Return Spring
Gasket F12415 2001 PRIUS (RM778U) Author: Date: 1531 BR–17 BRAKE – BRAKE MASTER CYLINDER Master Cylinder Body Clevis Lock Nut
Snap Ring 26 (265, 19)
No. 1 Piston
No. 2 Piston Clevis Cylinder Boot
Plug N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Lithium soap base glycol grease F12630 2001 PRIUS (RM778U) Author: Date: 1532 BR–24 BRAKE – FRONT BRAKE PAD BR1J3–01 REPLACEMENT 1. REMOVE FRONT WHEEL 2. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspection hole and replace the pads if they are not within the specification. Minimum thickness: 1.0mm (0.039 in.) F12057 3. (a) F12058 2001 PRIUS (RM778U) LIFT UP CALIPER Hold the sliding pin and remove the bottom side installation bolt. HINT: Do not disconnect the flexible hose from the brake caliper. (b) Lift up the caliper and suspend it securely. 4. REMOVE 2 PADS WITH 4 ANTI–SQUEAL SHIMS 5. REMOVE 2 PAD SUPPORT PLATES NOTICE: The support plates can be used again provided that they have sufficient rebound, no deformation, cracks or wear, and have had all rust, dirt and foreign particles cleaned off. 6. CHECK DISC THICKNESS AND RUNOUT (See page BR–29 ) 7. INSTALL PAD SUPPORT PLATES Install the 2 pad support plates. NOTICE: Do not assemble the upper and lower pad support plates in reverse. 8. INSTALL NEW PADS NOTICE: When replacing worn pads, the anti–squeal shims must be replaced together with the pads. (a) Apply disc brake grease to both side of the inner anti– squeal shim (See page BR–23). (b) Install the 2 anti– squeal shims on each pad. (c) Install the inner pad with the pad wear indicator plate facing upward. (d) Install the outer pad. NOTICE: There should be no oil or grease adhering to the friction surfaces of the pads or the disc. BR–25 BRAKE 9. (a) (b) – FRONT BRAKE PAD INSTALL CALIPER Draw out a small amount of brake fluid from the reservoir. Press in the piston with a hammer handle or similar implement. HINT:

F12060 (c) (d) 10. 11. 12. 2001 PRIUS (RM778U) Tape the hammer handle before use. If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid escape. Install the caliper. Hold the sliding pin and torque the installation bolts. Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) INSTALL FRONT WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) DEPRESS BRAKE PEDAL SEVERAL TIMES CHECK THAT FLUID LEVEL IS AT MAX LINE BR–33 BRAKE – REAR DRUM BRAKE BR14B–02 REMOVAL 1. INSPECT SHOE LINING THICKNESS Remove the inspection hole plug, and check the shoe lining thickness through the hole. If less than minimum, replace the shoes. Minimum thickness: 1.0 mm (0.039 in.) 2. REMOVE REAR WHEEL F12395 3. (a) F07782 REMOVE BRAKE DRUM Release the parking brake pedal, and remove the brake drum. HINT: If the brake drum cannot be removed easily, do the following steps. (b) Remove the plug and insert a screwdriver through the hole in the backing plate. (c) Using another screwdriver, reduce the brake shoe adjuster by turning the adjusting wheel. 4. REMOVE FRONT SHOE (a) Using SST, disconnect the return spring from the rear shoe. SST 09703–30010 (b) Using needle–nose pliers, remove the anchor spring. SST F12387 (c) (d) (e) (f) SST F12388 5. (a) 2001 PRIUS (RM778U) Using SST, remove the cap, shoe hold–down spring and pin from the front shoe. SST 09718–00010 Remove the adjuster and return spring together with the front shoe. Using needle–nose pliers, remove the adjusting lever spring. Remove the automatic adjusting lever from the front shoe. REMOVE REAR SHOE Using SST, remove the cap, shoe hole–down spring and pin. SST 09718–00010 BR–34 BRAKE (b) 6. (a) (b) – REAR DRUM BRAKE Using needle–nose pliers, disconnect the parking brake cable from the parking brake lever, and remove the rear shoe. REMOVE PARKING BRAKE LEVER Remove the C–washer. Remove the parking brake lever from the rear shoe. F09780 7. (a) SST (b) F12390 2001 PRIUS (RM778U) 8. (a) (b) (c) (d) REMOVE WHEEL CYLINDER Using SST, disconnect the brake line. Use container to catch the brake fluid. SST 09751–36011 Torque: 15 N·m (155 kgf·cm, 11 ft·lbf) Remove the bolt and the wheel cylinder. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) DISASSEMBLE WHEEL CYLINDER Remove the 2 boots from the wheel cylinder. Remove the 2 pistons from the wheel cylinder. Remove the spring from the wheel cylinder. Remove the 2 piston cups from each piston. BR–42 BRAKE – HYDRAULIC BRAKE BOOSTER BR0K8–14 COMPONENTS Wiper Arm 26 (270, 20) Cowl Top Ventilator Louver RH Cowl Top Ventilator Louver LH Hood to Cowl Top Seal Wiper Motor Cover 7.4 (75, 64 in.·lbf) Wiper Motor & Link Assembly 5.4 (55, 48 in.·lbf) Engine Room R/B No. 2 Lipuid and Suction Tube Outer Front Cowl Top Panel Hydraulic Brake Booster Assembly Reservoir 7.5 (77, 66 in.·lbf) Brake Reservoir Hose No. 1 Right Front Brake Line 15 (155, 11) 19 (194, 14) Clip 19 (194, 14) Clamp Clip Brake Reservoir Hose No. 2 Brake Actuator Hose Sub–bracket Clamp Bracket 19 (194, 14) 18 (184, 13) Reservoir Bracket N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part 2001 PRIUS (RM778U) 19 (194, 14) F12416 BR–43 BRAKE – HYDRAULIC BRAKE BOOSTER Brake Actuator Tube 15 (155, 11) 7.8 (80, 69 in.·lbf) Screw 2.9 (30, 26 in.·lbf) Clip Connector Bracket
Clamp Suction Hose Accumulator 54 (550, 36) Pressure Switch Assembly 7.8 (80, 69 in.·lbf)
O–Ring Brake Power Supply Bracket No. 2 7.8 (80, 69 in.·lbf) Spring Clip
Clamp Brake Booster Pump Bracket No. 2 Silencer Tube 7.8 (80, 69 in.·lbf) Brake Booster Pump Bracket No. 1 Cushion Washer Brake Power Supply Bracket No. 1 Cushion Collar 7.8 (80, 69 in.·lbf) Collar Sleeve Cushion Washer Booster Pump Brake Power Supply Bracket No. 3 7.8 (80, 69 in.·lbf) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part 2001 PRIUS (RM778U) F12665 BR–44 BRAKE – HYDRAULIC BRAKE BOOSTER BR1JJ–01 REMOVAL NOTICE: Before starting the work, make sure that the ignition switch is OFF and depress the brake pedal more than 40 times. HINT: When a pressure in power supply system is released, reaction force becomes heavy. NOTICE:
As high pressure is applied to the brake actuator tube, never deform it.
Until the work is over, do not turn the ignition switch ON. 1. DRAW OUT FLUID WITH SYRINGE NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. 2. REMOVE OUTER FRONT COWL TOP PANEL (See page BO–32) 3. REMOVE RESERVOIR, BRAKE ACTUATOR HOSE, BRAKE RESERVOIR HOSE NO. 1, NO. 2 AND RESERVOIR BRACKET (a) Disconnect the fluid level warning switch connector from the reservoir. (b) Remove the 2 bolts from the reservoir. Torque: 7.5 N·m (77 kgf·cm, 66 in.·lbf) (c) Disconnect the 3 hoses from the reservoir and remove the reservoir and 3 hoses. (d) Disconnect the 3 hoses from the reservoir bracket clamp. (e) Remove the 4 bolts and reservoir bracket. Torque: 18 N·m (184 kgf·cm, 13 ft·lbf) 4. (a) (b) F12385 2001 PRIUS (RM778U) DISCONNECT LIQUID AND SUCTION TUBES Disconnect the liquid and suction tubes (See page AC–25). Remove the nut and release the liquid and suction tubes. BR–45 BRAKE 5. (a) (b) – HYDRAULIC BRAKE BOOSTER REMOVE RIGHT FRONT BRAKE LINE Using SST and spanner, disconnect the right front brake line from the flexible hose and 2 way. SST 09023–00100 Torque: 15 N·m (155 kgf·cm, 11 ft·lbf) Pull out the brake line with the grommet from the body. SST Spanner F12380 6. DISCONNECT BRAKE LINE Using SST, disconnect the brake line from the hydraulic brake booster assembly. SST 09023–00100 Torque: 15 N·m (155 kgf·cm, 11 ft·lbf) ÎÎÎ ÎÎÎ SST F12383 7. DISCONNECT 2 CONNECTORS 8. (a) REMOVE HYDRAULIC BRAKE BOOSTER ASSEMBLY Remove the clamp, clamp bracket and 3 bolts. (b) Release the wire harness to remove the hydraulic brake booster assembly. F12381 F12504 F12624 2001 PRIUS (RM778U) BR–46 BRAKE (c) (d) (e) F12625 2001 PRIUS (RM778U) – HYDRAULIC BRAKE BOOSTER Remove the 3 installation bolts and a nut. Torque: 19 N·m (194 kgf·cm, 14 ft·lbf) Remove the hydraulic brake booster assembly. Remove the 2 bolts and sub–bracket. Torque: 19 N·m (194 kgf·cm, 14 ft·lbf) BR–56 BRAKE – REAR SPEED SENSOR BR1JL–01 REMOVAL F12503 (b) Mount the rear axle hub in a soft jaw vise. NOTICE: Replace the axle hub assembly if it is dropped or a strong shock is given to it. (c) Using SST and 2 bolts (Diameter: 12 mm, Pitch: 1.5 mm), remove the speed sensor. SST 09520–00031 (09520–00040, 09521–00020), 09950–00020 NOTICE:
If a damage is inflicted to the sensor rotor, replace the axle hub assembly.
Do not scratch the contacting surface of axle hub and speed sensor. SST Bolt 1. REMOVE REAR WHEEL 2. DISCONNECT SPEED SENSOR CONNECTOR Disconnect the connector from the speed sensor. 3. REMOVE SPEED SENSOR WITH REAR AXLE HUB (See page SA–46) 4. REMOVE SPEED SENSOR (a) Using a pin punch and hammer, drive out the 2 pins and remove the 2 attachments from SST. SST 09520–00031 Bolt SST F08657 5. (a) (b) F12076 2001 PRIUS (RM778U) IF NECESSARY, REPLACE SPEED SENSOR WIRE HARNESS Remove the seat cushion, seatback and quarter trim (See page BO–83). Disconnect the speed sensor wire harness connector. BR–57 BRAKE (c) (d) 2001 PRIUS (RM778U) – REAR SPEED SENSOR Remove the 2 bolts, 2 nuts holding the sensor harness from the lower arm and body. Torque: 5.5 N·m (56 kgf·cm, 49 in.·lbf) Replace the sensor wire harness with the grommet. SR–1 STEERING – STEERING SYSTEM STEERING SYSTEM SR08F–07 PRECAUTION

Care must be taken to replace parts properly because they could affect the performance of the steering system and result in a driving hazard. The PRIUS is equipped with SRS (Supplemental Restraint System) such as the driver airbag and passenger airbag. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices in the RS section. 2001 PRIUS (RM778U) Author: Date: 1574 SR–4 STEERING – TILT STEERING COLUMN TILT STEERING COLUMN SR1BE–01 COMPONENTS Steering Wheel Pad Shift Lever Assembly Upper Column Cover 8.0 (80, 69 in.·lbf) Torx Screw 50 (510, 37) 8.8 (90, 78 in.·lbf) Steering Wheel Torx Screw Steering Column Assembly 8.8 (90, 78 in.·lbf) Lower Ciolumn Cover Combination Switch (w/ Spiral Cable) 25 (260, 19) 35 (360, 26) Sliding Yoke No. 2 Intermediate Shaft Assembly Transmission Control Cable 25 (260, 19) 35 (360, 26) 4.0 (40, 35 in.·lbf) 35 (360, 26) Lower Instrument Finish Panel Column Hole Cover Shift Lock Computer Sub–assembly 49 (50, 43 in.·lbf) 49 (50, 43 in.·lbf) Main Shaft Lower Dust Seal Instrument Finish Panel Hood Lock Release Lever N·m (kgf·cm, ft·lbf) : Specified torque F12219 2001 PRIUS (RM778U) Author: Date: 1577 SR–5 STEERING – TILT STEERING COLUMN Transponder Key Coil
Energy Absorbing Clip Break Away Capsule Key Cylinder Column Upper Bracket Key Interlock Solenoid Key Unlock Warning Switch Column Upper Clamp Energy Absorbing Plate Energy Absorbing Plate Energy Absorbing Plate Guide Ignition Switch
Tapered–head Bolt Break Away Bracket Tilt Lever Lock Bolt
Snap Ring Tilt Steering Support Column Tube Sub–assembly 9.5 (100, 87 in.·lbf) Washer Tilt Lever Tilt Sub Lever No. 2 Tilt Lever Lock Bolt
Snap Ring 5.4 (55, 48 in.·lbf) No. 1 Tilt Steering Support Collar Steering Pawl Set Bolt Main Shaft Assembly Tilt Steering Adjust Nut 13 (130, 9) No. 1 Tilt Steering Support Reinforce Torsion Spring
Main Shaft Bushing N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Molybdenum disulfide lithium base grease F12238 2001 PRIUS (RM778U) Author: Date: 1578 SR–6 STEERING – TILT STEERING COLUMN SR1BF–01 REMOVAL 1. REMOVE STEERING WHEEL PAD NOTICE: If the airbag connector is disconnected with the ignition switch at ON, DTCs will be recorded. (a) Place the front wheels facing straight ahead. Torx Screw Case Torx Screw (b) Using a torx socket wrench, loosen the 2 torx screws until the groove along the screw circumference catches on the screw case. F12211 (c) Pull out the wheel pad from the steering wheel and disconnect the airbag connector. (d) Disconnect the connector. CAUTION:
When storing the wheel pad, keep the upper surface of the pad facing upward.
Never disassemble the wheel pad. NOTICE: When removing the wheel pad, take care not to pull the airbag wire harness. Airbag Connector Correct Wrong F12212 2. (a) (b) Matchmarks (c) SST 2001 PRIUS (RM778U) F12213 REMOVE STEERING WHEEL Remove the steering wheel set nut. Place matchmarks on the steering wheel and main shaft assembly. Using SST, remove the steering wheel. SST 09950–50012 (09951–05010, 09952–05010, 09953–05020, 09954–05020) SR–7 STEERING – TILT STEERING COLUMN 3. (a) REMOVE LOWER INSTRUMENT FINISH PANEL Remove the 2 screws and disconnect hood lock release lever. (b) Remove the screw and bolt. (c) Disconnect the connectors and DLC3, and remove the lower instrument finish panel. 4. REMOVE UPPER AND LOWER COLUMN COVERS (a) Remove the 3 screws and lower column cover. (b) Remove the screw and upper column cover. 5. REMOVE COMBINATION SWITCH WITH SPIRAL CABLE (a) Disconnect the connectors. (b) Disconnect the airbag connector. (c) Remove the 3 screws and combination switch with spiral cable. 6. REMOVE SPIRAL CABLE (See page BE–19) NOTICE: Do not disassemble the spiral cable or apply oil to it. 7. 8. DISCONNECT TRANSMISSION CONTROL CABLE REMOVE SHIFT LEVER ASSEMBLY (See page HT–50) 9. DISCONNECT COLUMN HOLE COVER Remove the 3 clips and disconnect the column hole cover. 10. REMOVE SHIFT LOCK COMPUTER SUB–ASSEMBLY Remove the screw and shift lock computer sub–assembly. F12830 11. A B Matchmarks F12214 2001 PRIUS (RM778U) DISCONNECT NO. 2 INTERMEDIATE SHAFT ASSEMBLY (a) Place matchmarks on the No. 2 intermediate shaft assembly and control valve shaft. (b) Loosen the bolt ”A” and remove the bolt ”B”, then disconnect the No. 2 intermediate shaft assembly from the control valve shaft. 12. REMOVE INSTRUMENT FINISH PANEL Remove the 3 screws and instrument finish panel. 13. REMOVE STEERING COLUMN ASSEMBLY (a) Disconnect the connectors. (b) Remove the 2 bolts, 2 nuts and steering column assembly. 14. REMOVE NO. 2 INTERMEDIATE SHAFT ASSEMBLY Remove the bolt and No. 2 intermediate shaft assembly from the sliding yoke. 15. REMOVE SLIDING YOKE Remove the bolt and sliding yoke from the main shaft assembly. 16. REMOVE COLUMN HOLE COVER SR–8 STEERING 17. (a) (b) (c) F12215 2001 PRIUS (RM778U) – TILT STEERING COLUMN REMOVE MAIN SHAFT LOWER DUST SEAL Remove the 2 nuts and parking brake cable bracket. Remove the 2 bolts and disconnect the accelerator pedal. Remove the 3 nuts and main shaft lower dust seal. SR–9 STEERING – TILT STEERING COLUMN SR1BG–01 DISASSEMBLY NOTICE: When using a vise, do not overtighten it. 1. REMOVE TRANSPONDER KEY COIL Remove the screw and transponder key coil. 2. REMOVE COLUMN UPPER BRACKET AND COLUMN UPPER CLAMP (a) Using a centering punch, mark the center of the 2 tapered–head bolts. (b) Using a 3 – 4 mm (0.12 – 0.16 in.) drill, drill into the 2 bolts. (c) 3. (a) (b) (c) Screw Extractor Using a screw extractor, remove the 2 bolts, column upper bracket and column upper clamp. REMOVE TILT STEERING SUPPORT Remove the look nut. Remove the washer, steering pawl set bolt and tilt steering support. Remove the 2 No. 1 tilt steering support collars. F12223 4. (a) (b) REMOVE 2 ENERGY ABSORBING PLATES Using pliers, remove the 2 energy absorbing clips. Remove the 2 energy absorbing plates, 2 energy absorbing guides, and 2 break away capsules. F12235 5. REMOVE TORSION SPRING Using a screw driver, remove the torsion spring. F12225 2001 PRIUS (RM778U) SR–10 STEERING 6. (a) – TILT STEERING COLUMN REMOVE TILT LEVER AND BREAK AWAY BRACKET Remove No. 2 tilt lever lock bolt and No. 1 tilt steering support reinforce. HINT: This bolt is left–handed one. F12226 (b) Remove the tilt steering adjusting nut, tilt lever, tilt sub lever, tilt lever lock bolt and break away bracket. HINT: This bolt is left–handed one. 7. REMOVE MAIN SHAFT ASSEMBLY AND MAIN SHAFT BUSHING (a) Using a snap ring expander, remove the snap ring on the upper side. F12227 (b) (c) (d) F12228 2001 PRIUS (RM778U) Using a brass bar and a hammer, tap out the main shaft assembly with the main shaft bushing. Remove the main shaft bushing. Using a snap ring expander, remove the snap ring on the lower side. SR–12 STEERING – TILT STEERING COLUMN SR1BI–01 REASSEMBLY NOTICE: When using a vise, do not overtighten it. 1. COAT PARTS INDICATED BY ARROWS WITH MOLYBDENUM DISULFIDE LITHIUM BASE GREASE (See page SR–4) 2. INSTALL MAIN SHAFT ASSEMBLY (a) Using a snap ring expander, install a new snap ring on the lower side. (b) Install the main shaft assembly. (c) Using a snap ring expander, install a new snap ring on the upper side. 3. (a) SST (b) 4. (a) F12231 HINT: Align the holes in the break away bracket with the projections of the tilt lever lock bolt and tilt sub lever. (b) F12232 2001 PRIUS (RM778U) INSTALL MAIN SHAFT BUSING Coat a new bushing with molybdenum disulfide lithium base grease. Using SST and a hammer, tap in the main shaft bushing. SST 09608–06041 INSTALL BREAK AWAY BRACKET AND TILT LEVER Install break away bracket, tilt lever lock bolt, tilt sub lever and tilt lever. Install the tilt steering adjusting nut by rotating it counterclockwise. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) SR–13 STEERING (c) – TILT STEERING COLUMN Install the No. 1 tilt steering support reinforce with the No. 2 tilt lever lock bolt by turning it counterclockwise. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) HINT: Align the No. 1 support reinforce with the nut to eliminate looseness by turning the No. 1 support reinforce counterclockwise a little, then torque the No. 2 tilt lever lock bolt. F12233 5. 6. (a) INSTALL TORSION SPRING INSTALL 2 ENERGY ABSORBING PLATES Install the 2 break away capsules, 2 energy absorbing guides and 2 energy absorbing plates. (b) 7. (a) (b) Install the 2 new energy absorbing clips. INSTALL TILT STEERING SUPPORT Install the 2 No. 1 tilt steering support collars. Install the tilt steering support, steering pawl set bolt, washer. Install the lock nut. Torque: 9.5 N·m (100 kgf·cm, 87 in.·lbf) F12234 (c) F12236 8. (a) (b) F12224 2001 PRIUS (RM778U) INSTALL COLUMN UPPER BRACKET AND COLUMN UPPER CLAMP Install the column upper bracket and column upper clamp with 2 new tapered–head bolts. Tighten the 2 tapered–head bolts until the bolt heads break off. SR–14 STEERING – TILT STEERING COLUMN SR1BJ–01 INSTALLATION 1. (a) (b) F12215 B Matchmarks F12214 2001 PRIUS (RM778U) (c) Install the parking brake cable bracket with the 2 nuts. 2. INSTALL COLUMN HOLE COVER 3. INSTALL SLIDING YOKE Install the sliding yoke to the main shaft assembly with the bolt. Torque: 35 N·m (360 kgf·cm, 26 ft·lbf) 4. INSTALL NO. 2 INTERMEDIATE SHAFT ASSEMBLY Temporarily install the No. 2 intermediate shaft assembly to the sliding yoke with the bolt. 5. INSTALL STEERING COLUMN ASSEMBLY (a) Install the steering column assembly with the 2 bolts and 2 nuts. Torque: 25 N·m (260 kgf·cm, 19 ft·lbf) (b) Connect the connectors. 6. INSTALL INSTRUMENT FINISH PANEL Install the instrument finish panel with the 3 screws. 7. (a) A INSTALL MAIN SHAFT LOWER DUST SEAL Install the main shaft lower dust seal with the 3 nuts. Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf) Connect the accelerator pedal with the 2 bolts. CONNECT NO. 2 INTERMEDIATE SHAFT ASSEMBLY Align the matchmarks on the No. 2 intermediate shaft assembly and control valve shaft. (b) Install the bolt ”B” and torque the bolt ”A”. Torque: 35 N·m (360 kgf·cm, 26 ft·lbf) 8. INSTALL SHIFT LOCK COMPUTER SUB–ASSEMBLY Install the shift lock computer sub–assembly with the screw. 9. CONNECT COLUMN HOLE COVER Connect the column hole cover with the 3 clips. 10. INSTALL SHIFT LEVER ASSEMBLY (See page HT–52) SR–15 STEERING 11. 12. 13. (a) F12830 (b) (c) 14. (a) (b) 15. (a) (b) (c) 16. (a) (b) (c) Marks F08459 2001 PRIUS (RM778U) – TILT STEERING COLUMN CONNECT TRANSMISSION CONTROL CABLE INSTALL SPIRAL CABLE (See page BE–19) INSTALL COMBINATION SWITCH WITH SPIRAL CABLE Install the combination switch with spiral cable with the 3 screws. Connect the airbag connector. Connect the connectors. INSTALL UPPER AND LOWER COLUMN COVERS Install the upper column cover with the screw. Install the lower column cover with the 3 screws. INSTALL LOWER INSTRUMENT FINISH PANEL Connect the connectors and DLC3 and install the lower instrument finish panel. Install the screw and bolt. Connect the hood lock release lever with the 2 screws. CENTER SPIRAL CABLE Check that the front wheels are facing straight ahead. Turn the cable counterclockwise by hand until it becomes harder to turn. Then rotate the cable clockwise about 2.5 turns to align the marks. HINT: The cable will rotate about 2.5 turns to either left or right of the center. 17. INSTALL STEERING WHEEL (a) Align the matchmarks on the steering wheel and main shaft assembly. (b) Install the steering wheel set nut. Torque: 50 N·m (510 kgf·cm, 37 ft·lbf) 18. INSTALL STEERING WHEEL PAD NOTICE:
Never use airbag parts from another vehicle. When replacing parts, replace with new ones.
Make sure the wheel pad is installed with the specified torque.
If the wheel pad has been dropped, or there are cracks, dents or other defects in the case or connector, replace the wheel pad with a new one.
When installing the wheel pad, take care that the wirings do not interfere with other parts and that they are not pinched between other parts. (a) Connect the connector. (b) Connect the airbag connector. SR–16 STEERING Torx Screw Torx Screw Case (c) (d) 19. 20. F12217 2001 PRIUS (RM778U) – TILT STEERING COLUMN Install the steering wheel pad after confirming that the circumference groove of the torx screws is caught on the screw case. Using a torx socket wrench, torque the 2 screws. Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf) CHECK STEERING WHEEL CENTER POINT PERFORM CALIBRATION OF TORQUE SENSOR ZERO POINT (See page DI–454) SR–17 STEERING – ELECTRIC POWER STEERING GEAR ELECTRIC POWER STEERING GEAR SR1BK–01 COMPONENTS EMPS Bracket No. 2 Intermediate Shaft Assembly 5.5 (60, 52 in.·lbf) 5.5 (60, 52 in.·lbf) 35 (360, 26)
Cotter Pin Electric Power Steering Gear Assembly
83 (850, 61) 49 (500, 36)
83 (850, 61)
Cotter Pin
74 (760, 55) 83 (850, 61) Rack Housing No. 2 Bracket 49 (500, 36) Rack Housing No. 2 Grommet 74 (760, 55) 19 (190, 14) Stabilizer Bar 19 (190, 14) 142 (1450, 105) 137 (4,400, 101) Suspension Member 137 (1,400, 101) 142 (1,450, 105) LH Engine Under Cover 137 (1,400, 101) Torque Rod 100 (1,020, 74) 137 (1,400, 101) 142 (1,450, 105) LH Engine Under Cover N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part F12851 2001 PRIUS (RM778U) Author: Date: 1590 SR–18 STEERING – ELECTRIC POWER STEERING GEAR Tie Rod End Lock Nut 56 (570, 41) Clip Rack Boot Clamp Rack End 83 (850, 61) * 62 (630, 46)
Claw Washer Earth Wire 5.5 (60, 52 in.·lbf)
Claw Washer PS Gear Assembly with Motor Rack End 83 (850, 61) * 62 (630, 46) Clamp Rack Boot Clip Lock Nut 56 (570, 41) Tie Rod End N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part * For use with SST F12262 2001 PRIUS (RM778U) Author: Date: 1591 SR–19 STEERING – ELECTRIC POWER STEERING GEAR SR1BL–01 REMOVAL NOTICE: Remove the steering wheel assembly before the steering gear removal, because there is possibility of breaking of the spiral cable. 1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 2. REMOVE STEERING WHEEL PAD (See page SR–6) 3. REMOVE STEERING WHEEL (See page SR–6) 4. REMOVE RH AND LH ENGINE UNDER COVERS 5. DISCONNECT RH AND LH TIE ROD ENDS (See page SA–9) 6. DISCONNECT STABILIZER BAR (See page SA–41) 7. DISCONNECT LOWER SUSPENSION ARM FROM LOWER BALL JOINT (See page SA–41) 8. DISCONNECT 2 CONNECTORS AND EMPS BRACKET (a) Disconnect the 2 connectors. (b) Disconnect the 2 clamps. (c) (d) Remove the bolt and disconnect the earth wire. Remove the 2 bolts and EMPS bracket. 9. DISCONNECT NO. 2 INTERMEDIATE SHAFT ASSEMBLY Place the matchmarks on the No. 2 intermediate shaft assembly and control valve shaft. Loosen the bolt ”A” and remove the bolt ”B” then disconnect the No. 2 intermediate shaft assembly from the control valve shaft. DISCONNECT TORQUE ROD (See page SA–41) REMOVE SUSPENSION MEMBER AND ELECTRIC POWER STEERING GEAR ASSEMBLY (See page SA–41) REMOVE ELECTRIC POWER STEERING GEAR ASSEMBLY Remove the stabilizer bar (See page SA–41). F12196 A (a) B (b) F12214 10. 11. 12. (a) 2001 PRIUS (RM778U) SR–20 STEERING (b) (c) F12197 2001 PRIUS (RM778U) – ELECTRIC POWER STEERING GEAR Remove the 4 bolts and electric power steering gear assembly from the front suspension member. Remove the bracket and grommet from the electric power steering gear assembly. SR–21 STEERING – ELECTRIC POWER STEERING GEAR SR1BM–01 DISASSEMBLY NOTICE: When using a vise, do not overtighten it. 1. SECURE ELECTRIC POWER STEERING GEAR ASSEMBLY IN VISE Using SST, secure the electric power steering gear assembly in a vise. SST 09612 – 00012 SST F12264 2. Matchmarks F07501 REMOVE RH AND LH TIE ROD ENDS AND LOCK NUTS (a) Place matchmarks on the tie rod end, lock nut and rock end. (b) Loosen the lock nut and remove the tie rod end and lock nut. (c) Employ the same manner described above to the other side. 3. REMOVE RH AND LH CLAMPS, CLIPS AND RACK BOOTS (a) Remove the clamp, clip and rack boot. NOTICE: Be careful not to damage the boot. HINT: Mark the RH and LH rack boots. (b) Employ the same manner described above to the other side. 4. REMOVE RH AND LH RACK ENDS CLAW WASHERS (a) Using a screwdriver and a hammer, unstake the washer. NOTICE: Avoid any impact on the steering rack. F12265 (b) SST F12266 2001 PRIUS (RM778U) Using a spanner, hold the steering rack steadily and using SST, remove the rack end. SST 09922 – 10010 NOTICE: Use SST 09922 – 10010 in the direction shown in the illustration. HINT: Mark the RH and LH rack ends. (c) Remove the claw washer. SR–22 STEERING (d) – ELECTRIC POWER STEERING GEAR Employ the same manner described above to the other side. 5. REMOVE EARTH WIRE Remove the bolt and earth wire. 2001 PRIUS (RM778U) SR–23 STEERING – ELECTRIC POWER STEERING GEAR SR1BN–01 REASSEMBLY NOTICE: When using a vise, do not overtighten it. 1. INSTALL EARTH WIRE Install the earth wire with the bolt. Torque: 5.5 N·m (60 kgf·cm, 52 in.·lbf) 2. (a) INSTALL RH AND LH CLAW WASHERS AND RACK ENDS Install a new claw washer and temporarily install the rack end. HINT: Align the claws of the claw washer with the steering rack grooves. F12267 (b) SST Fulcrum Length F12268 Using a spanner, hold the steering rack steadily and using SST, torque the rack end. SST 09922 – 10010 Torque: 62 N·m (630 kgf·cm, 46 ft·lbf) NOTICE: Use SST 09922 – 10010 in the direction shown in the illustration. HINT: Use a torque wrench with a fulcrum length of 380 mm (14.96 in.). (c) Using a brass bar and a hammer, stake the claw washer. NOTICE: Avoid any impact on the steering rack. (d) Employ the same manner described above to the other side. F12269 3. (a) INSTALL RH AND LH RACK BOOTS, CLIPS AND CLAMPS Ensure that the steering rack hole is not clogged with grease. HINT: If the hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned. (b) Install the boot, clip and clamp. NOTICE: Be careful not to damage or twist the boot. 2001 PRIUS (RM778U) SR–24 STEERING Matchmarks Employ the same manner described above to the other side. 4. (a) INSTALL RH AND LH TIE ROD ENDS AND LOCK NUT Screw the lock nut and tie rod end onto the rack end and the matchmarks aligned. After adjusting toe–in. torque the nut (See page SA–4). Employ the same manner described above to the other side. (c) 2001 PRIUS (RM778U) ELECTRIC POWER STEERING GEAR (c) (b) F07501 – SR–25 STEERING – ELECTRIC POWER STEERING GEAR SR1BO–01 INSTALLATION 1. (a) INSTALL ELECTRIC POWER STEERING GEAR ASSEMBLY Install the grommet and bracket to the electric power steering gear assembly. HINT: Install the bracket with the inscribed mark facing to the front of the vehicle. Front F12847 (b) (c) Install the electric power steering gear assembly with the 4 new bolts to the front suspension member. Torque: 83 N·m (850 kgf·cm, 61 ft·lbf) Install the stabilizer bar (See page SA–43). F12197 (d) To prevent the main shaft lower dust seal from damaging, wind vinyl tape on the serrated part of the control valve shaft. (e) Turn over the main shaft lower dust seal from the engine compartment side to the cab. INSTALL SUSPENSION MEMBER AND ELECTRIC POWER STEERING GEAR ASSEMBLY (See page SA–43) CONNECT TORQUE ROD (See page SA–43) Serrated Part F15034 Main Shaft Lower Dust Seal 2. Body Cab Side 3. Engine Compartment Side F15035 2001 PRIUS (RM778U) SR–26 STEERING 4. (a) (b) (c) (d) 5. F12196 6. 7. (a) (b) A B (c) (d) Matchmarks F12214 8. – ELECTRIC POWER STEERING GEAR CONNECT EMPS BRACKET AND 2 CONNECTORS Connect the EMPS bracket with the 2 bolts. Torque: 5.5 N·m (60 kgf·cm, 52 in.·lbf) Connect the earth wire with the bolt. Torque: 5.5 N·m (60 kgf·cm, 52 in.·lbf) Connect the 2 clamps. Connect the 2 connectors. CONNECT LOWER SUSPENSION ARM TO LOWER BALL JOINT (See page SA–43) CONNECT STABILIZER BAR (See page SA–43) CONNECT NO. 2 INTERMEDIATE SHAFT ASSEMBLY Put the dust seal back to the engine compartment side. Remove the vinyl tape from the serrated part of the control valve shaft. Align the matchmarks on the No. 2 intermediate shaft assembly and control valve shaft. Install the bolt ”B” and torque the bolt ”A”. Torque: 35 N·m (360 kgf·cm, 22 ft·lbf) CONNECT RH AND LH TIE ROD ENDS (See page SA–14) PLACE FRONT WHEELS FACING STRAIGHT AHEAD 9. HINT: Do it with the front of the vehicle jacked up. 10. CENTER SPIRAL CABLE (See page SR–14) 11. INSTALL STEERING WHEEL (a) Align the matchmarks on the steering wheel and steering column main shaft. (b) Temporarily tighten the steering wheel set nut. 12. CHECK STEERING WHEEL CENTER POINT 13. TORQUE STEERING WHEEL SET NUT Torque: 50 N·m (510 kgf·cm, 37 ft·lbf) 14. INSTALL STEERING WHEEL PAD (See page SR–14) 15. CHECK FRONT WHEEL ALIGNMENT 16. PERFORM CALIBRATION OF TORQUE SENSOR ZERO POINT (See page DI–454) 2001 PRIUS (RM778U) RS–1 SUPPLEMENTAL RESTRAINT SYSTEM – SRS AIRBAG SRS AIRBAG RS0JO–06 PRECAUTION CAUTION:
The PRIUS is equipped with SRS, which comprises a driver airbag, front passenger airbag and side airbag. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when required. Before performing servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedures described in the repair manual.
Work must be started 90 seconds after the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery. (The SRS is equipped with a back–up power source so that if work is started within 90 seconds from disconnecting the negative (–) terminal cable of the battery, the SRS may be deployed.)
Do not expose the steering wheel pad, front passenger airbag assembly, side airbag assembly, airbag sensor assembly, front airbag sensor or side airbag sensor assembly directly to hot air or flames. NOTICE:
Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery.
Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, side airbag assembly, airbag sensor assembly, front airbag sensor and side airbag sensor assembly should be inspected. (See page RS–14, RS–28, RS–41, RS–53, RS–58 and RS–63)
Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs.
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
Never disassemble and repair the steering wheel pad, front passenger airbag assembly, side airbag assembly, airbag sensor assembly, front airbag sensor or side airbag sensor assembly in order to reuse it.
If the steering wheel pad, front passenger airbag assembly, side airbag assembly, airbag sensor assembly, front airbag sensor or side airbag sensor assembly has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace it with new one.
Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting the system’s electrical circuits.
Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices.
After work on the SRS is completed, perform the SRS warning light check (See page DI–497).
When the negative (–) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as they were before and adjust the clock. To avoid erasing the memory in each memory system, never use a back– up power supply from outside the vehicle.
If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section. 2001 PRIUS (RM778U) Author: Date: 1600 RS–2 SUPPLEMENTAL RESTRAINT SYSTEM – SRS AIRBAG RS0R8–01 OPERATION 1. STEERING WHEEL PAD (with AIRBAG) The inflater and bag of the SRS are stored in the steering wheel pad and cannot be disassembled. The inflater contains a squib, igniter charge, gas generator, etc., and inflates the bag when instructed by the airbag sensor assembly. H15220 2. SPIRAL CABLE (in COMBINATION SWITCH) A spiral cable is used as an electrical joint from the vehicle body side to the steering wheel. Spiral Cable R09725 3. FRONT PASSENGER AIRBAG ASSEMBLY The inflater and bag of the SRS are stored in the front passenger airbag assembly and cannot be disassembled. The inflater contains a squib, igniter charge, gas generator, etc., and inflates the bag when instructed by the airbag sensor assembly. H15507 4. SIDE AIRBAG ASSEMBLY The inflater and bag of the SRS side airbag are stored in the side airbag assembly and cannot be disassembled. The inflater contains a squib, igniter charge, gas generator, etc., and inflates the bag when instructed by the side airbag sensor assembly. H15678 5. SEAT BELT PRETENSIONER The seat belt pretensioner system is a component of the front seat outer belt. The pretensioner contains a squib, gas generator, wire, piston, etc., and operates in the event of a frontal collision. The seat belt pretensioner cannot be disassembled. H15676 2001 PRIUS (RM778U) RS–3 SUPPLEMENTAL RESTRAINT SYSTEM – SRS AIRBAG 6. SRS WARNING LIGHT The SRS warning light is located on the combination meter. It goes on to alert the driver of trouble in the system when a malfunction is detected in the airbag sensor assembly self–diagnosis. In normal operation conditions when the ignition switch is turned to the ON position, the light goes on for about 6 seconds and then goes off. H15218 H15513 7. AIRBAG SENSOR ASSEMBLY The airbag sensor assembly is mounted on the floor inside the lower center finish panel. The airbag sensor assembly consists of an airbag sensor, safing sensor, diagnosis circuit, ignition control, drive circuit, etc. It receives signals from the airbag sensor, front airbag sensor, side airbag sensor assembly and door side airbag assembly and judges whether the SRS must be activated or not. The airbag sensor assembly cannot be disassembled. 8. FRONT AIRBAG SENSOR The front airbag sensor is mounted inside each of the side members. The sensor unit is a mechanical type. When the sensor detects deceleration force above a predetermined limit, contact is made in the sensor, sending a signal to the airbag sensor assembly. The front airbag sensor cannot be disassembled. H15517 9. SIDE AIRBAG SENSOR ASSEMBLY The side airbag sensor assembly is mounted in the LH and RH center pillars. The side airbag sensor assembly consists of a lateral deceleration sensor, safing sensor, diagnosis circuit, etc. It sends signals to the airbag sensor assembly to judge whether the SRS side airbag must be activated or not. The side airbag sensor assembly cannot be disassembled. H15675 2001 PRIUS (RM778U) RS–4 SUPPLEMENTAL RESTRAINT SYSTEM – SRS AIRBAG 10. SRS CONNECTORS HINT: SRS connectors are located as shown in the following illustration. 7 8 9 11 10 2 Airbag Sensor Assembly 1 Side Airbag Sensor Assembly (RH) Side Airbag Assembly (RH) (Squib) Seat Belt Pretensioner (RH) Front Airbag Sensor (RH) 6 Front Passenger Airbag Assembly (Squib) 5 Steering Wheel Pad (Squib) Spiral Cable 4 3 13 12 Front Airbag Sensor (LH) 14 Seat belt Pretensioner (LH) 15 Side Airbag Assembly (LH) (Squib) 16 Side Airbag Sensor Assembly (LH) H15711 No. Item (1) Terminal Twin–Lock Mechanism Connectors 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16 (2) Airbag Activation Prevention Mechanism Connectors 1, 2, 3, 4, 5, 6, 8, 9, 14, 15 (3) Electrical Connection Check Mechanism Connectors 1, 2, 3 2001 PRIUS (RM778U) Application RS–5 SUPPLEMENTAL RESTRAINT SYSTEM (a) – All connectors in the SRS are colored in yellow to distinguish them from other connectors. Connectors having special functions and specifically designed for the SRS are used in the locations shown on the previous page to ensure high reliability. These connectors use durable gold–plated terminals. (1) Spacer Housing (2) Female Male Z05953 When Connector is Connected SRS AIRBAG Terminal Twin–Lock Mechanism Each connector has a two–piece component consisting of a housing and a spacer. This design enables the terminal to be locked securely by two locking devices (the retainer and the lance) to prevent terminals from coming out. Airbag Activation Prevention Mechanism Each connector contains a short spring plate. When the connector is disconnected, the short spring plate automatically connects positive (+) terminal and negative (–) terminal of the squib. When Connector is Disconnected Short Spring Plate Short Spring Plate Housing Contacting Male Terminal Housing Short Spring Plate ON Terminal Squib Connectors 2001 PRIUS (RM778U) Short Spring Plate Squib Closed Circuit R10587 RS–6 SUPPLEMENTAL RESTRAINT SYSTEM – SRS AIRBAG HINT: The type of connector is shown in the diagram on the previous page. (3) SRS Warning Light Disconnection Detection Pin Airbag Sensor Assembly Electrical Connection Check Mechanism This mechanism electrically checks that connectors are connected correctly and completely. The electrical connection check mechanism is designed so that the disconnection detection pin connects with the diagnosis terminals when the connector housing lock is locked. R12076
Half Connection
Complete Connection Terminal for Diagnosis Terminal for Diagnosis Disconnection Detection Pin H01315 HINT: The illustration shows connectors ”1”, ”2” and ”3” in step 11. 2001 PRIUS (RM778U) RS–7 SUPPLEMENTAL RESTRAINT SYSTEM When the vehicle is involved in a frontal collision in the hatched area (Fig. 1) and the shock is larger than the predetermined level, the SRS is activated automatically. A safing sensor is designed to go on at a smaller deceleration rate than the airbag sensor. As illustrated in Fig. 2, ignition is caused when current flows to the squib, which happens when a safing sensor and the deceleration sensor go on simultaneously. When a deceleration force acts on the sensors, 2 squibs in the driver airbag and front passenger airbag ignite and generate gas. The gas discharging into the driver airbag and front passenger airbag rapidly increases the pressure inside the bags, breaking open the steering wheel pad and instrument panel. Bag inflation then ends, and the bags deflate as the gas is discharged through discharge holes at the bag’s rear or side. 11. DISCONNECTION OF CONNECTORS FOR FRONT AIRBAG SENSOR AND SIDE AIRBAG SENSOR While holding both flank sides of the outer, slide the outer to the direction shown by an arrow. Lock of the connectors is released, then disconnect the connectors. Power Source Fig.2 SRS AIRBAG (b) Fig.1 Safing Sensor – Squibs Deceleration Sensor Z14034 Outer (a) (b) H01581 HINT: Be sure to hold both flank sides of the outer. If holding the top and bottom sides, it will obstruct disconnection. Lock of connector is released Disconnection is completed H01582 2001 PRIUS (RM778U) RS–8 SUPPLEMENTAL RESTRAINT SYSTEM 12. – SRS AIRBAG CONNECTION OF CONNECTORS FOR FRONT AIRBAG SENSOR AND SIDE AIRBAG SENSOR Outer Outer H01583 (a) Align the male connector (of the side of sensor) and female connector in the same direction as shown in the illustration and fit in them without rubbing. (b) As they are fitted in, the outer slides rearward. Press it until the outer returns to its original position again. If fitting stops half way, connectors will separate. (c) Be sure to insert until they are locked. After fitting in, pull them slightly to check that they are locked. (When locked, make sure that the outer returns to its original position and sound at the time of fitting in can be heard.) HINT:  Do not fit in while holding the outer.  When fitting in, the outer slides. Do not touch it. 2001 PRIUS (RM778U) RS–9 SUPPLEMENTAL RESTRAINT SYSTEM 13. (a) (b) (c) – SRS AIRBAG DISCONNECTION OF SIDE AIRBAG CONNECTOR Place a finger on the slider. Slide the slider to release lock. Disconnect the connector. Slider Slider Disconnection is completed H01584 14. Slider CONNECTION OF SIDE AIRBAG CONNECTOR Slider H01585 2001 PRIUS (RM778U) RS–10 SUPPLEMENTAL RESTRAINT SYSTEM (a) (b) – SRS AIRBAG Align a lock part of male connector and a slider of female connector in the same direction as shown in the illustration, fit in them without rubbing. Be sure to insert until they are locked. After fitting in pull them slightly to check that they are locked. (When locked, make sure that the outer returns to its original position and sound at the time of fitting in can be heard.) HINT:   As the slider slides, do not touch it. Be careful not to deform the release board. If the release board is deformed, replace it with a new one. 15. DISCONNECTION OF CONNECTORS FOR STEERING WHEEL PAD (with AIRBAG) AND FRONT PASSENGER AIRBAG ASSEMBLY Place a finger on the slider. Slide the slider to release lock. Disconnect the connector. (a) (b) (c) Slider Slider Disconnection is completed H01586 2001 PRIUS (RM778U) RS–11 SUPPLEMENTAL RESTRAINT SYSTEM 16. (a) (b) – SRS AIRBAG CONNECTION OF CONNECTORS FOR STEERING WHEEL PAD (with AIRBAG) AND FRONT PASSENGER AIRBAG ASSEMBLY Align a lock part of male connector and a slider of female connector in the same direction as shown in the illustration, fit in them without rubbing. Be sure to insert until they are locked. After fitting in pull them slightly to check that they are locked. (When locked, make sure that the outer returns to its original position and sound at the time of fitting in can be heard.) HINT:   Slider As the slider slides, do not touch it. Be careful not to deform the release board. If the release board is deformed, replace it with a new one. Slider H01587 2001 PRIUS (RM778U) RS–14 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE RS0JS–07 INSPECTION 1. (a) (b) H15220 2. (a) (b) Vehicle not involved in collision: INSPECT SUPPLEMENTAL RESTRAINT SYSTEM Do a diagnostic system check (See page DI–497). Do a visual check which includes the following item with the steering wheel pad (with airbag) installed in the vehicle. Check cuts, minute cracks or marked discoloration on the steering wheel pad top surface and in the grooved portion. Vehicle involved in collision and airbag is not deployed: INSPECT SUPPLEMENTAL RESTRAINT SYSTEM Do a diagnostic system check (See page DI–497). Do a visual check which includes the following items with the steering wheel pad (with airbag) removed from the vehicle.
Check cuts, minute cracks or marked discoloration on the steering wheel pad top surface and in the grooved portion.
Check cuts and cracks in wire harness, and chipping in connectors. H16239 Horn Button Contact Plate H16240 H15220 2001 PRIUS (RM778U)
Check the deformation of the horn button contact plate of the steering wheel. CAUTION: For removal and installation of the steering wheel pad, see page SR–6 and SR–14, be sure to follow the correct procedure. HINT:
If the horn button contact plate of the steering wheel is deformed, never repair it. Always replace the steering wheel assembly with a new one.
There should be no interference between the steering wheel pad and steering wheel, and the clearance should be uniform all the way around when the new steering wheel pad is installed on the steering wheel. RS–15 SUPPLEMENTAL RESTRAINT SYSTEM 3. (a) Horn Button Contact Plate H16240 2001 PRIUS (RM778U) STEERING WHEEL PAD AND SPIRAL CABLE Vehicle involved in collision and airbag is deployed: INSPECT SUPPLEMENTAL RESTRAINT SYSTEM Do a diagnostic system check (See page DI–497). (b) Do a visual check which includes the following items with the steering wheel pad (with airbag) removed from the vehicle.
Check the deformation on the horn button contact plate of the steering wheel.
Check the damage on the spiral cable connector and wire harness. CAUTION: For removal and installation of the steering wheel pad, see page SR–6 and SR–14, and be sure to follow the correct procedure. HINT:
If the horn button contact plate of the steering wheel is deformed, never repair it. Always replace the steering wheel assembly with a new one.
H15220 – There should be no interference between the steering wheel pad and steering wheel, and the clearance should be uniform all the way around when the new steering wheel pad is installed on the steering wheel. RS–16 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE RS0R3–02 DISPOSAL HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with airbag), always first deploy the airbag in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION:
Never dispose of a steering wheel pad which has an undeployed airbag.
The airbag produces a sizeable exploding sound when it deploys, so perform the operation out–of– doors and where it will not create a nuisance to nearby residents.
SST

AB0152


1. Battery SST AB0158 2001 PRIUS (RM778U) When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. SST 09082–00700 When deploying an airbag, perform the operation at least 10 m (33 ft) away from the steering wheel pad. The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. Always wash your hands with water after completing the operation. Do not apply water, etc. to a steering wheel pad with the deployed airbag. AIRBAG DEPLOYMENT WHEN SCRAPPING VEHICLE HINT: Have a battery ready as the power source to deploy the airbag. RS–17 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE (a) Check functioning of the SST. CAUTION: When deploying the airbag, always use the specified SST: SRS Airbag Deployment Tool. SST 09082–00700 SST AB0152 (1) Battery SST Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (–) terminal. HINT: Do not connect the yellow connector which will be connected with the supplemental restraint system. AB0158 (2) Press the SST activation switch, and check that the LED of the SST activation switch lights up. CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is probable, so definitely do not use the SST. (3) Disconnect the SST from the battery. SST H01580 (b) Install the SST. CAUTION: Check that there is no looseness in the steering wheel and steering wheel pad. (1) While turning the steering wheel right / left, remove the 3 screws and column lower cover. (2) Disconnect the airbag connector of the spiral cable. H15221 (3) Connect the connectors of the 2 SST to the airbag connector of the spiral cable. SST 09082–00700, 09082–00760 NOTICE: To avoid damaging the connector of the SST and wire harness, do not lock the secondary lock of the twin lock. SST 2001 PRIUS (RM778U) H16242 RS–18 SUPPLEMENTAL RESTRAINT SYSTEM (4) Battery – STEERING WHEEL PAD AND SPIRAL CABLE Move the SST at least 10 m (33 ft) away from the front of the vehicle. Close all the doors and windows of the vehicle. (5) NOTICE: Take care not to damage the SST wire harness. (6) Connect the SST red clip to the battery positive (+) terminal and the black clip to the negative (–) terminal. SST 10 m (33 ft) or more R13455 (c) R06753 2001 PRIUS (RM778U) Deploy the airbag. (1) Check that no one is inside the vehicle or within 10 m (33 ft) area around the vehicle. (2) Press the SST activation switch and deploy the airbag. CAUTION:
The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a steering wheel pad with the deployed airbag.
When scrapping a vehicle, deploy the airbag and scrap the vehicle with the steering wheel pad still installed.
When moving a vehicle for scrapping which has a steering wheel pad with deployed airbag, use gloves and safety glasses. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. 2. DEPLOYMENT WHEN DISPOSING OF STEERING WHEEL PAD ONLY NOTICE:
When disposing of the steering wheel pad (with airbag) only, never use the customers vehicle to deploy the airbag.
Be sure to follow the procedure given below when deploying the airbag. HINT: Have a battery ready as the power source to deploy the airbag. RS–19 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE (a) Remove the steering wheel pad (See page SR–6). CAUTION:
When removing the steering wheel pad, work must be started 90 seconds after the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery.
When storing the steering wheel pad, keep the upper surface of the pad facing upward. (b) Wire Harness Diameter Stripped Wire Harness Section AB0163 Using a service–purpose wire harness tie down the steering wheel pad to the disc wheel. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.0019 in2. or more) CAUTION: If a wire harness which is too thin or some other thing is used to tie down the steering wheel pad, it may be snapped by the shock when the airbag is deployed. This is highly dangerous. Always use a wire harness for vehicle use which is at least 1.25 mm2 (0.0019 in2.). HINT: To calculate the square of the stripped wire harness section: Square = 3.14 x (Diameter)2 divided by 4 (1) L M H16243 2001 PRIUS (RM778U) Install the 2 bolts with washers in the 2 bolt holes in the steering wheel pad. Bolt: L: 35. mm (1.387 in.) M: 6.0 mm (0.236 in.) Pitch: 1.0 mm (0.039 in.) NOTICE:
Tighten the bolts by hand until the bolts become difficult to turn.
Do not tighten the bolts too much. RS–20 SUPPLEMENTAL RESTRAINT SYSTEM (2) – STEERING WHEEL PAD AND SPIRAL CABLE Using 3 wire harness, wind the wire harness at least 2 times each around the bolts installed on the left and right sides of the steering wheel pad. CAUTION:
Tightly wind the wire harness around the bolts so that there is no slack.
If there is slackness in the wire harness, the steering wheel pad may come loose due to the shock when the airbag is deployed. This is highly dangerous. 2 Times or more H16244 (3) H16245 Battery SST AB0158 2001 PRIUS (RM778U) Face the upper surface of the steering wheel pad upward. Separately tie the left and right sides of the steering wheel pad to the disc wheel through the hub nut holes. Position the steering wheel pad connector so that it hangs downward through a hub hole in the disc wheel. CAUTION:
Make sure that the wire harness is tight. It is very dangerous when looseness in the wire harness results in the steering wheel pad coming free due to the shock from the airbag deploying.
Always tie down the steering wheel pad with the pad side facing upward. It is very dangerous if the steering wheel pad is tied down with the metal surface facing upward as the wire harness will be cut by the shock from the airbag deploying and the steering wheel pad will be thrown into the air. NOTICE: The disc wheel will be marked by airbag deployment, so when disposing of the airbag use a redundant disc wheel. (c) Check functioning of the SST (See step 1–(a)). SST 09082–00700 RS–21 SUPPLEMENTAL RESTRAINT SYSTEM SST H16246 – STEERING WHEEL PAD AND SPIRAL CABLE (d) Install the SST. CAUTION: Place the disc wheel on the level ground. (1) Connect the connectors of the 2 SST to the steering wheel pad connector. SST 09082–00700, 09082–00760 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the disc wheel. (2) Move the SST to at least 10 m (33 ft) away from the steering wheel pad tied down on the disc wheel. 10 m (33 ft) or more H03207 (e) Y Y Weight 2001 PRIUS (RM778U) X H03205 Cover the steering wheel pad with a cardboard box or tires.
Covering method using a cardboard box: Cover the steering wheel pad with the cardboard box and weight the cardboard box down in 4 places with at least 190 N (20 kg, 44 lb). Size of cardboard box: Must exceed the following dimensions: X = 460 mm (18.11 in.) Y = 650 mm (25.59 in.) NOTICE:
When dimension Y of the cardboard box exceeds the diameter of the disc wheel with tire to which the steering wheel pad is tied, X should be the following size. X = 460 mm (18.11 in.) + width of tire
If a cardboard box smaller than the specified size is used, the cardboard box will be broken by the shock from the airbag deployment. RS–22 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE
Inner Diam. Width Tires (3 or More) H03206 Covering method using tires: Place at least 3 tires without disc wheel on top of the disc wheel with tire to which the steering wheel pad is tied. Tire size: Must exceed the following dimensions– Width: 185 mm (7.87 in.) Inner diameter: 360 mm (14.17 in.) CAUTION: Do not use tires with disc wheels. NOTICE: The tires may be marked by the airbag deployment, so use the redundant tires. (f) Deploy the airbag. (1) Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (–) terminal. (2) (3) Check that no one is within 10 m (33 ft) area around the disc wheel which the steering wheel pad is tied to. Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. 10 m (33 ft) or more H03207 H03208 2001 PRIUS (RM778U) (g) Dispose of the steering wheel pad (with airbag). CAUTION:
The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a steering wheel pad with the deployed airbag. (1) Remove the steering wheel pad from the disc wheel. (2) Place the steering wheel pad in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. RS–23 SUPPLEMENTAL RESTRAINT SYSTEM 3. H03208 2001 PRIUS (RM778U) – STEERING WHEEL PAD AND SPIRAL CABLE DEPLOYMENT WHEN DISPOSING OF STEERING WHEEL PAD WITH AIRBAG DEPLOYED IN COLLISION Dispose of the steering wheel pad (with airbag). CAUTION:
The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
When moving a vehicle for scrapping which has a steering wheel pad with the deployed airbag, use gloves and safety glasses.
Use gloves and safety glasses when handling a steering wheel pad with deployed airbag.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a steering wheel pad with deployed airbag. (1) Remove the steering wheel pad from the steering wheel (See page SR–6). (2) Place the steering wheel pad in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. RS–28 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS0R5–01 INSPECTION 1. (a) (b) H15507 2. (a) (b) H15709 2001 PRIUS (RM778U) Vehicles not involved in collision: INSPECT SUPPLEMENTAL RESTRAINT SYSTEM Do a diagnostic system check (See page DI–497). Do a visual check which includes the following item with the front passenger airbag assembly installed in the vehicle. Check cuts, minute cracks or marked discoloration on the front passenger airbag assembly and instrument panel. Vehicle involved in a collision and airbag is not deployed: INSPECT SUPPLEMENTAL RESTRAINT SYSTEM Do a diagnostic system check (See page DI–497). Do a visual check which includes the following items with the front passenger airbag assembly removed from the vehicle.
Check cuts, minute cracks or marked discoloration on the front passenger airbag assembly.
Check cuts and cracks in wire harness, and for chipping in connectors.
Check the deformation or cracks on the instrument panel and instrument panel reinforcement. CAUTION: For removal and installation of the front passenger airbag assembly, see page RS–27 and RS–38, and be sure to follow the correct procedure. HINT: If the instrument panel or instrument panel reinforcement is deformed or cracked, never repair it. Always replace it with a new one. 3. Vehicle involved in a collision and airbag is deployed: INSPECT SUPPLEMENTAL RESTRAINT SYSTEM (a) Do a diagnostic system check (See page DI–497). (b) Do a visual check which includes the following items with the front passenger airbag assembly removed from the vehicle.
Check the deformation or cracks on the instrument panel and instrument panel reinforcement.
Check the damage on the connector and wire harness. RS–29 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY CAUTION: For removal and installation of the front passenger airbag assembly, see page SR–6 and SR–14, and be sure to follow the correct procedure. HINT: If the instrument panel or instrument panel reinforcement is deformed or cracked, never repair it. Always replace it with a new one. 2001 PRIUS (RM778U) RS–30 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS0JZ–06 DISPOSAL HINT: When scrapping vehicle equipped with an SRS or disposing of a front passenger airbag assembly, always first deploy the airbag in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION:
Never dispose of a front passenger airbag assembly which has an undeployed airbag.
The airbag produces a sizeable exploding sound when it deploys, so perform the operation out–of– doors and where it will not create a nuisance to nearby residents.
SST

AB0152


1. AIRBAG DEPLOYMENT WHEN SCRAPPING VEHICLE HINT: Have a battery ready as the power source to deploy the airbag. (a) Check functioning of the SST (See step 1–(a) on page RS–16). SST 09082–00700 Battery SST AB0158 2001 PRIUS (RM778U) When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. SST 09082–00700 When deploying an airbag, perform the operation at least 10 m (33 ft) away from the front passenger airbag assembly. The front passenger airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. Use gloves and safety glasses when handling a front passenger airbag assembly with the deployed airbag. Always wash your hands with water after completing the operation. Do not apply water, etc. to a front passenger airbag assembly with the deployed airbag. RS–31 SUPPLEMENTAL RESTRAINT SYSTEM (b) H15519 – FRONT PASSENGER AIRBAG ASSEMBLY Disconnect the airbag connector. (1) Using a screwdriver, pry out the glove compartment door finish plate inside the lower panel. HINT: Tape the screwdriver tip before use. (2) Remove the connector from the glove compartment door finish plate. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (3) Disconnect the airbag connector. (c) Install the SST. (1) Connect the connectors of the 2 SST to the front passenger airbag assembly connector. SST 09082–00700, 09082–00760 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. SST H15510 (2) Battery Move the SST to at least 10 m (33 ft) away from the front of the vehicle. Close all the doors and windows of the vehicle. (3) NOTICE: Take care not to damage the SST wire harness. (4) Connect the SST red clip to the battery positive (+) terminal and the black clip to the negative (–) terminal. SST 10 m (33 ft) or more R13455 (d) H03286 2001 PRIUS (RM778U) Deploy the airbag. (1) Check that no one is inside the vehicle or within 10 m (33 ft) area around the vehicle. (2) Press the SST activation switch and deploy the airbag. RS–32 SUPPLEMENTAL RESTRAINT SYSTEM H15709 2001 PRIUS (RM778U) – FRONT PASSENGER AIRBAG ASSEMBLY CAUTION:
The front passenger airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling the front passenger airbag assembly with the deployed airbag.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to the front passenger airbag assembly with the deployed airbag.
When scrapping a vehicle, deploy the airbag and scrap the vehicle with the front passenger airbag assembly still installed.
When moving a vehicle for scrapping which has the front passenger airbag assembly with the deployed airbag, use gloves and safety glasses. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. 2. DEPLOYMENT WHEN DISPOSING OF FRONT PASSENGER AIRBAG ASSEMBLY ONLY NOTICE:
When disposing of the front passenger airbag assembly only, never use the customer’s vehicle to deploy the airbag.
Be sure to follow the procedure given below when deploying the airbag. HINT: Have a battery ready as the power source to deploy the airbag. (a) Remove the front passenger airbag assembly (See page RS–27). CAUTION:
When removing the front passenger airbag assembly, work must be started 90 seconds after the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery.
When storing the front passenger airbag assembly, keep the upper surface of the airbag deployment side facing upward. RS–33 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY (b) Wire Harness Diameter Stripped Wire Harness Section AB0163 Using a service–purpose wire harness, tie down the front passenger airbag assembly to the tire. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.0019 in.2 or more) CAUTION: If the front passenger airbag assembly is tied down with too thin wire harness, it may snap. This is highly dangerous. Always use a wire harness which is at least 1.25 mm2 (0.0019 in2.). HINT: To calculate the square of the stripped wire harness section: Square = 3.14 X (Diameter)2 divided by 4 (1) Install the 2 nuts on the front passenger airbag assembly. (2) Wind the wire harness around the bolts, and pass the wire harness though the installation holes. H15511 H15512 (3) Position the front passenger airbag assembly inside the tire with the airbag deployment side facing inside. Tire size: Must exceed the following dimensions– Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) Width Inner diam. H11963 2001 PRIUS (RM778U) RS–34 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY CAUTION:
Make sure that the wire harness is tight. It is very dangerous if looseness in the wire harness results in the front passenger airbag assembly coming free due to the shock from the airbag deploying.
Always tie down the front passenger airbag assembly with the airbag deployment side facing inside. NOTICE: The tire will be marked by the airbag deployment, so when disposing of the airbag use a redundant tire. (c) Check functioning of the SST (See step 1–(a) on page RS–16). SST 09082–00700 (d) Place the tires. (1) Place at least 2 tires under the tire to which the front passenger airbag assembly is tied. (2) Place at least 2 tires over the tire to which the front passenger airbag assembly is tied. The top tire should have the wheel installed. Battery SST AB0158 Tires (5 or more) H11964 (3) Tie the tires together with 2 wire harness. CAUTION: Make sure that the wire harness is tight. It is very dangerous if loose wire harnesses result in the tires coming free due to the shock from the airbag deploying. HINT: Place the SST connector and wire harness inside tires. Provide at least 1 m (3 ft) of slack for the wire harness. R05403 2001 PRIUS (RM778U) RS–35 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY (e) Battery SST Front Passenger Airbag Assembly 10 m (33 ft) or more R09690 R09687 Install the SST. Connect the connectors of the 2 SST to the front passenger airbag assembly connector. SST 09082–00700, 09082–00760 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tires. (f) Deploy the airbag. (1) Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (–) terminal. (2) Check that no one is within 10 m (33 ft) area around the tire which the front passenger airbag assembly is tied to. (3) Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. (g) Dispose of the front passenger airbag assembly. CAUTION:
The front passenger airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a front passenger airbag assembly with the deployed airbag.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a front passenger airbag assembly with the deployed airbag. (1) Remove the front passenger airbag assembly from the tire. (2) Place the front passenger airbag assembly in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. 3. DEPLOYMENT WHEN DISPOSING OF FRONT PASSENGER AIRBAG ASSEMBLY WITH AIRBAG DEPLOYED IN COLLISION Dispose of the front passenger airbag assembly. R09687 2001 PRIUS (RM778U) RS–36 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY CAUTION:
The front passenger airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a front passenger airbag assembly with the deployed airbag.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a front passenger airbag assembly with the deployed airbag. (1) Remove the front passenger airbag assembly from the instrument panel (See page RS–27). (2) Place the front passenger airbag assembly in a vinyl bag, tie the end tightly and dispose of it in the same way so as other general parts disposal. 2001 PRIUS (RM778U) RS–42 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG ASSEMBLY RS0RA–01 DISPOSAL HINT: When scrapping vehicles equipped with an SRS or disposing of the side airbag assembly always first deploy the airbag in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION:
Never dispose of a side airbag assembly which has an undeployed airbag.
The airbag produces a sizeable exploding sound when it deploys, so perform the operation out–of– doors and where it will not create a nuisance to nearby residents.
SST

AB0152


1. Battery SST AB0158 2001 PRIUS (RM778U) When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool), perform the operation in a place away from electrical noise. SST 09082–00700 When deploying an airbag, perform the operation at least 10 m (33 ft) away from the airbag assembly. The side airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. Use gloves and safety glasses when handling side airbag assembly with the deployed airbag. Always wash your hands with water after completing the operation. Do not apply water, etc. to a side airbag assembly with the deployed airbag. AIRBAG DEPLOYMENT WHEN SCRAPPING VEHICLE HINT: Have a battery ready as the power source to deploy the airbag. (a) Check functioning of the SST (See step 1–(a) on page RS–16). SST 09082–00700 RS–43 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG ASSEMBLY (b) Disconnect the side airbag connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. H15678 (c) Install the SST. (1) Connect the connectors of the 2 SST to the airbag connector. SST 09082–00700, 09082–00750 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. SST Battery H15679 (2) Battery Move the SST at least 10 m (33 ft) away from the front of the vehicle. Close all the doors and windows of the vehicle. (3) NOTICE: Take care not to damage the SST wire harness. (4) Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (–) terminal. SST 10 m (33 ft) or more R13455 (d) H15680 2001 PRIUS (RM778U) Deploy the airbag. (1) Check that no one is inside the vehicle or within 10 m (33 ft) area around the vehicle. (2) Press the SST activation switch and deploy the airbag. CAUTION:
The side airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling the side airbag assembly with the deployed airbag.
Do not apply water, etc. to the side airbag assembly with the deployed airbag.
Always wash your hands with water after completing the operation.
When scrapping a vehicle, deploy the airbag and scrap the vehicle with the side airbag assembly still installed. RS–44 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG ASSEMBLY HINT: The airbag deploys simultaneously as the LED of SST activation switch lights up. 2. DEPLOYMENT WHEN DISPOSING OF SIDE AIRBAG ASSEMBLY NOTICE:
When disposing of the side airbag assembly only, never use the customer’s vehicle to deploy the airbag.
Be sure to follow the procedure given below when deploying the airbag. HINT: Have a battery ready as the power source to deploy the airbag. (a) Remove the seatback assembly (See page RS–40). (b) Disengage the hook of the seatback cover as shown in the illustartion. H15413 (c) Remove the 2 nuts and side airbag assembly from the seatback assembly. CAUTION: When storing the side airbag assembly, keep the upper surface of the airbag deployment side facing upward. H15412 (d) Wire Harness Diameter Stripped Wire Harness Section AB0163 2001 PRIUS (RM778U) Using a service–purpose wire harness, tie down the side airbag assembly to the tire. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.0019 in2. or more) CAUTION: If a wire harness which is too thin or some other thing is used to tie down the side airbag assembly, it may be snapped by the shock when the airbag is deployed. This is highly dangerous. Always use a wire harness for vehicle use which is at least 1.25 mm2 (0.0019 in2.). RS–45 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG ASSEMBLY HINT: To calculate the square of the stripped wire harness section– Square = 3.14 x (Diameter)2 divided by 4 (1) Install the 2 nuts to the side airbag assembly. (2) Wind the wire harness around the stud bolts of the side airbag assembly as shown in the illustration. H15681 H15682 (3) H15683 2001 PRIUS (RM778U) Position the side airbag assembly inside the tire with the airbag deployment direction facing inside. Tire size: Must exceed the following dimensions– Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) CAUTION:
Make sure the wire harness is tight. It is very dangerous when a loose wire harness results in the side airbag assembly coming free due to the shock from the airbag deploying.
Always tie down the side airbag assembly with the airbag deployment side facing inside. NOTICE: The tire will be marked by the airbag deployment, so when disposing of the airbag use a redundant tire. RS–46 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG ASSEMBLY (e) Check functioning of the SST (See step 1–(a) on page RS–16). SST 09082–00700 (f) Place the tires. (1) Place at least 2 tires under the tire to which the side airbag assembly is tied. (2) Place at least 2 tires over the tire to which the side airbag assembly is tied. The top tire should have the wheel installed. Battery SST AB0158 Tires (5 or More) H01336 (3) Tie the tires together with 2 wire harness. CAUTION: Make sure that the wire harness are tight. It is very dangerous when loose wire harness results in the tires coming free due to the shock from the airbag deploying. HINT: Place the SST connector and wire harness inside tires. Secure at least 1 m (3 ft) of slack for the wire harness. R05403 (g) Battery SST Side Airbag Assembly 10 m (33 ft) or more 2001 PRIUS (RM778U) H01337 Install the SST. Connect the connectors of the 2 SST to the side airbag assembly connector. SST 09082–00700, 09082–00750 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire. (h) Deploy the airbag. (1) Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (–) terminal. (2) Check that no one is within 10 m (33 ft) area around the tire which the side airbag assembly is tied to. (3) Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. RS–47 SUPPLEMENTAL RESTRAINT SYSTEM H00544 2001 PRIUS (RM778U) SIDE AIRBAG ASSEMBLY (i) Dispose of the side airbag assembly. CAUTION:
The side airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a side airbag assembly with the deployed airbag.
Do not apply water etc. to a side airbag assembly with the deployed airbag.
Always wash your hands with water after completing the operation. (1) Remove the side airbag assembly from the tire. (2) Place the side airbag assembly in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. 3. H00544 – DEPLOYMENT WHEN DISPOSING OF SIDE AIRBAG ASSEMBLY WITH AIRBAG DEPLOYED IN COLLISION Dispose of the side airbag assembly. CAUTION:
The side airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a side airbag assembly with the deployed airbag.
Do not apply water etc. to a side airbag assembly with the deployed airbag.
Always wash your hands with water after completing the operation. (1) Remove the side airbag assembly from the seat (See page RS–40 and see step 2). (2) Place the side airbag assembly in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. RS–49 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG ASSEMBLY RS0RB–01 INSTALLATION NOTICE: Never use airbag parts from another vehicle. When replacing parts, replace them with new parts. 1. (a) INSTALL SEATBACK ASSEMBLY Install the seatback assembly to the seat adjuster with the 4 bolts. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) H15368 (b) Install 5 new hog rings. HINT: When installing the hog rings, take care to prevent wrinkles as little as possible. H11975 2. INSTALL SEAT CUSHION ASSEMBLY Install the seat cushion assembly. H11974 3. (a) (b) 4. H15461 2001 PRIUS (RM778U) INSTALL FRONT SEAT CUSHION SHIELDS Install the inner front seat cushion shield with the 2 screws. Employ the same manner described above to the other side. INSTALL RECLINING ADJUSTER RELEASE HANDLE RS–50 SUPPLEMENTAL RESTRAINT SYSTEM H15460 2001 PRIUS (RM778U) – SIDE AIRBAG ASSEMBLY 5. INSTALL FRONT SEAT NOTICE: When mounting the seat to the vehicle, take care not to damage the airbag wire harness. (a) Connect the side airbag connector. (b) Slide the front seat to the most front position. NOTICE: Make sure that seat adjuster locks. (c) Without holding the seat track handle, mount the seat to the vehicle. HINT: If holding the seat track handle, the adjusted rearmost position slip off. (d) Tighten the bolts on the front side temporarily, from the bolt on the inner side tighten them completely. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) (e) Slide the seat to the most front position to install the bolts on the rear side. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) (f) Install the 2 seat track covers. BE–1 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM BODY ELECTRICAL SYSTEM BE0OM–08 PRECAUTION HINT: Take care to observe the following precautions when performing inspections or removal and replacement of body electrical related parts. 1. HEADLIGHT SYSTEM Halogen bulbs have pressurized gas inside and require special handling. They can burst if scratched or dropped. Hold a bulb only by its plastic or metal case. Don’t touch the glass part of a bulb with bare hands. 2. SRS (SUPPLEMENTAL RSTRAINT SYSTEM) The PRIUS is equipped with an SRS (Supplemental Restraint System) such as the driver airbag, side airbag and front passenger airbag. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices in the RS section. 2001 PRIUS (RM778U) Author: Date: 1668 BE–2 BODY ELECTRICAL – TROUBLESHOOTING TROUBLESHOOTING BE16S–02 PROBLEM SYMPTOMS TABLE IGNITION SWITCH: This system uses the multiplex communication system, so check diagnosis system of the multiplex communication system before you proceed with troubleshooting. Symptom Ignition switch is not set to each position. Suspect Area See page 3. Ignition switch 4. Power source circuit BE–17 – KEY UNLOCK WARNING SWITCH: This system uses the multiplex communication system, so check diagnosis system of the multiplex communication system before you proceed with troubleshooting. Symptom Key unlock warning system does not operate. (The buzzer sounds when the ignition key is ACC or ON) Suspect Area 1. 2. 3. 4. 5. See page Ignition Switch Key Unlock Warning Switch Wire Harness Body ECU Combination Meter BE–17 BE–17 – – – HEADLIGHT AND TAILLIGHT SYSTEM: This system uses the multiplex communication system, so check diagnosis system of the multiplex communication system before you proceed with troubleshooting. Symptom Suspect Area See page Auto turn–off system does not operate when the driver’s door is opened. 1. Drivers Door Courtesy Switch 2. Body ECU BE–27 DI–678 Auto turn–off system: Headlight and taillight do not come on. 1. Body ECU 2. Wire Harness DI–678 – Auto turn–off system: Headlight and taillight stay on. 1. Body ECU 2. Wire Harness DI–678 – w/o Daytime Running Light System: Symptom Suspect Area See page Only one headlight comes on. 1. Bulb 2. Wire Harness – – ”LO–Beam” does not light (All). 1. Headlight Control Relay 2. Wire Harness BE–20 – ”LO–Beam” does not light (One side). 1. 2. 3. 4. – BE–12 BE–12 – ”HI–Beam” does not light (All). 1. Headlight Dimmer Switch 2. Wire Harness BE–20 – ”HI–Beam” does not light (One side). 1. 2. 3. 4. Bulb HEAD LH Fuse HEAD RH Fuse Wire Harness – BE–12 BE–12 – ”Flash” does not light. 1. 2. 3. 4. HEAD LH Fuse HEAD RH Fuse Headlight Dimmer Switch Wire Harness BE–12 BE–12 BE–20 – ”Flash” does not light. 1. Bulb 2. Wire Harness Bulb HEAD LH Fuse HEAD RH Fuse Wire Harness – – 2001 PRIUS (RM778U) Author: Date: 1669 BE–3 BODY ELECTRICAL – TROUBLESHOOTING Headlight does not come on. 1. Headlight Control Relay 2. Wire Harness BE–20 – Headlight does not come on. 1. Bulb 2. Wire Harness – – Headlight flickers. 1. Bulb 2. Wire Harness – – Headlight is dark. 1. Bulb 2. Wire Harness – – Only one taillight comes on. 1. Bulb 2. Wire Harness – – Taillight does not come on. (Headlight is normal) 1. 2. 3. 4. Taillight does not come on. (Headlight does not light) 1. Light Control Switch 2. Wire Harness TAIL Fuse Taillight Control Relay Light Control Switch Wire Harness BE–12 BE–42 BE–20 – BE–20 – w/ Daytime Running Light System: Symptom Suspect Area See page Only one headlight comes on. 1. 2. 3. 4. Daytime Running Light Relay Daytime Running Light Main Relay Bulb Wire Harness BE–20 BE–20 – – ”LO–Beam” does not light (All). 1. Headlight Control Relay 2. Wire Harness BE–20 – ”LO–Beam” does not light (One side). 1. 2. 3. 4. – BE–12 BE–12 – ”HI–Beam” does not light (All). 1. Headlight Dimmer Switch 2. Daytime Running Light Main Relay 3. Combination Meter BE–20 BE–20 – ”HI–Beam” does not light (One side). 1. 2. 3. 4. 5. Bulb HEAD HI (LH) Fuse HEAD HI (RH) Fuse Daytime Running Light No.2 Relay Wire Harness – BE–12 BE–12 BE–20 – ”Flash” does not light. 1. Headlight Dimmer Switch 2. Daytime Running Light Main Relay 3. Wire Harness BE–20 BE–20 – Headlight does not come on. 1. 2. 3. 4. 5. 6. 7. 8. BE–20 BE–20 BE–20 BE–20 BE–20 DI–678 – – Headlight does not come on with light control switch in HEAD. 1. Light Control Switch 2. Body ECU 3. Wire Harness BE–20 DI–678 – Headlight does not go out with light control switch in OFF. 1. Headlight Control Relay 2. Body ECU 3. Wire Harness BE–20 DI–678 – Bulb HEAD LO (LH) Fuse HEAD LO (RH) Fuse Wire Harness Headlight Control Relay Daytime Running Light Main Relay Daytime Running Light No.2 Relay Headlight Dimmer Switch Light Control Switch Body ECU Wire Harness Bulb 2001 PRIUS (RM778U) Author: Date: 1670 BE–4 BODY ELECTRICAL – TROUBLESHOOTING Headlight flickers. 1. Bulb 2. Wire Harness – – Headlight is dark. 1. Bulb 2. Wire Harness – – Taillight does not come on with light control switch in TAIL. 1. Taillight Control Relay 2. Wire Harness BE–20 – Taillight does not go out with light control switch in OFF. 1. Taillight Control Relay 2. Wire Harness BE–20 – Headlight does not come on with engine running and light control switch in OFF. 1. 2. 3. 4. 5. 6. 7. 8. BE–12 BE–12 BE–20 BE–20 – DI–678 BE–42 – ECU–B Fuse GAUGE Fuse Daytime Running Light Main Relay Daytime Running Light Relay Alternator L Terminal Body ECU Parking Brake Switch Wire Harness TURN SIGNAL AND HAZARD WARNING SYSTEM Symptom Suspect Area See page ”Hazard” and ”Turn” do not light up. 1. 2. 3. 4. 5. GAUGE Fuse TURN HAZ Fuse Ignition Switch Turn Signal Flasher Relay Wire Harness BE–12 BE–12 BE–17 BE–25 – Hazard warning light does not light up. (Turn is normal) 1. Hazard Warning Switch 2. Wire Harness BE–25 – Turn signal does not light up. (Hazard is normal) 1. Turn Signal Switch 2. Wire Harness BE–25 – Turn signal does not light up in one direction. 1. Turn Signal Switch 2. Wire Harness BE–25 – Only one bulb does not light up. 1. Bulb 2. Wire Harness – – INTERIOR LIGHT SYSTEM This system uses the multiplex communication system, so check diagnosis system of the multiplex communication system before you proceed with troubleshooting. Symptom Suspect Area See page All the lights do not come ON. DOME Fuse BE–12 The driver door courtesy light does not come ON when the driver’s door is opened. 1. Driver’s Door Courtesy Switch 2. Wire Harness 3. Body ECU BE–27 – – The passenger door courtesy light does not come ON when the passenger’s door is opened. 1. Passenger’s Door Courtesy Switch 2. Wire Harness 3. Body ECU BE–27 – DI–678 The room light does not come on when the rear–right door is opened. 1. 2. 3. 4. Rear–Right Door Courtesy Switch Wire Harness Body ECU Room Light BE–27 – DI–678 – The room light does not come on when the rear–left door is opened. 1. 2. 3. 4. Rear–Left Door Courtesy Switch Wire Harness Body ECU Room Light BE–27 – DI–678 – Only one of the bulbs comes ON. Bulb – 2001 PRIUS (RM778U) Author: Date: 1671 BE–5 BODY ELECTRICAL – TROUBLESHOOTING The illumination does not fade out when all the doors are closed. 1. Courtesy Switch 2. Wire Harness 3. Body ECU BE–27 – DI–678 The illumination does not fade out immediately when the ignition switch is turned to ACC or ON within 15 seconds after all the doors are closed. 1. 2. 3. 4. 5. BE–17 BE–12 BE–12 – DI–678 The illumination does not fade out immediately when all the doors are locked within 15 seconds after they are closed. 1. Door Unlock Detection Switch 2. Wire Harness 3. Body ECU BE–62 – DI–678 Interior light does not light up. (in front personal light) 1. Bulb 2. Personal Light 3. Wire Harness – BE–27 – Front personal light does not light up. 1. Bulb 2. Personal Light 3. Wire Harness – BE–27 – Rear personal light does not light up. 1. Bulb 2. Interior Light 3. Wire Harness – BE–27 – Luggage compartment light does not light up. 1. Bulb 2. Luggage Compartment Door Courtesy Switch 3. Wire Harness – BE–27 – Courtesy light does not light up. 1. 2. 3. 4. – BE–27 – DI–678 Ignition Switch ECU–B Fuse GAUGE Fuse Wire Harness Body ECU Bulb Door Courtesy Switch Wire Harness Body ECU BACK–UP LIGHT SYSTEM Symptom Suspect Area See page Back–Up Light does not light up. 1. 2. 3. 4. 5. GAUGE Fuse Ignition Switch Back–up Light Relay Wire Harness Bulb BE–12 BE–17 BE–30 – – Back–Up Light remains always on. 1. Bulb 2. Wire Harness – – Only one light does not light up. 1. Bulb 2. Wire Harness – – STOP LIGHT SYSTEM Symptom Suspect Area See page Stop light does not light up. 1. STOP Fuse 2. Stop Light Switch 3. Wire Harness BE–12 BE–32 – Stop light always lights up. 1. Stop Light Switch 2. Wire Harness BE–32 – Only one light always lights up. Wire Harness – Only one light does not light up. 1. Bulb 2. Wire Harness – – 2001 PRIUS (RM778U) Author: Date: 1672 BE–6 BODY ELECTRICAL – TROUBLESHOOTING WIPER AND WASHER SYSTEM Symptom Suspect Area See page Wipers and washer do not operate. 1. 2. 3. 4. WIPER Fuse Wiper Switch Wiper Motor Wire Harness BE–12 BE–34 BE–34 – Wipers do not operate in LO, HI or MIST. 1. Wiper Switch 2. Wiper Motor 3. Wire Harness BE–34 BE–34 – Wipers do not operate in INT. 1. Wiper Switch 2. Wiper Motor 3. Wire Harness BE–34 BE–34 – Washer motor does not operate. 1. 2. 3. 4. WASHER Fuse Washer Switch Washer Motor Wire Harness BE–12 BE–34 BE–34 – Wipers do not operate when washer switch ON. 1. 2. 3. 4. WASHER Fuse Washer Switch Wiper Motor Wire Harness BE–12 BE–34 BE–34 – Washer fluid does not operate. Washer Hose and Nozzle
When wiper switch is in HI position, the wiper blade is in contact with the body.
When the wiper switch is OFF, the wiper blade does not retract or the retract position is wrong. 1. Wiper Motor *1 2. Wire harness *1 – BE–34 – *1: Inspect wiper arm and blade set positions. Meter Gauges and Illumination: COMBINATION METER Symptom Suspect Area See page Fuel Gauge and Water Temperature Gauge does not operate. 1. GAUGE Fuse 2. Meter Circuit Plate 3. Wire Harness – BE–39 – Speedometer does not operate. 1. Vehicle Speed Sensor 2. Meter Circuit Plate 3. Wire Harness BE–42 BE–39 – Tachometer does not operate. 1. 2. 3. 4. – – BE–39 – Fuel Gauge does not operate or abnormal operation. 1. Fuel Tank Assembly 2. Wire Harness All illumination lights do not light up. 1. TAIL Fuse 2. Meter Circuit Plate 3. Wire Harness Only one illumination light does not light up. 1. Bulb 2. Wire Harness Igniter Engine and ECT ECU Meter Circuit Plate Wire Harness – – – BE–42 – – – 2001 PRIUS (RM778U) Author: Date: 1673 BE–7 BODY ELECTRICAL – TROUBLESHOOTING Warning Lights: COMBINATION METER Symptom Suspect Area See page Warning light do not light up. (Except Discharge, Open Door and SRS) 1. 2. 3. 4. GAUGE Fuse Meter Circuit Plate DC/DC converter Wire Harness – BE–39 – – Fuel Level warning light does not light up. 1. 2. 3. 4. Bulb Meter Circuit Plate Fuel Tank Assembly Wire Harness – BE–39 – – Low Oil Pressure warning light does not light up. 1. 2. 3. 4. Bulb Low Oil Pressure Warning Switch Meter Circuit Plate Wire Harness – BE–42 BE–39 – ABS warning light does not light up. 1. Bulb 2. ABS ECU 3. Wire Harness – DI–351 – Seat Belt warning light does not light up. 1. 2. 3. 4. Bulb Buckle Switch Meter Circuit Wire Harness – BE–42 BE–42 – Brake warning light does not light up. 1. 2. 3. 4. 5. Bulb Parking Brake Switch Brake Fluid Level Warning Switch Meter Circuit Plate Wire Harness – BE–42 BE–42 BE–39 – SRS Warning light does not light up. 1. 2. 3. 4. Bulb Airbag Sensor Assembly Meter Circuit Plate Wire Harness – DI–495 BE–39 – Open Door warning light does not light up. 1. 2. 3. 4. 5. DOME Fuse Bulb Door Courtesy Switch Meter Circuit Plate Wire Harness – – BE–27 BE–39 – Indicator Lights: COMBINATION METER Symptom Suspect Area See page High beam indicator light does not light up. 1. 2. 3. 4. Bulb Meter Circuit Plate Wire Harness Headlight System – BE–39 – BE–20 Turn indicator light does not light up. 1. 2. 3. 4. Bulb Meter Circuit Plate Wire Harness Turn Signal and Hazard Warning System – BE–39 – BE–25 Malfunction indicator light does not light up. 1. 2. 3. 4. Bulb ECM Meter Circuit Plate Wire Harness – – BE–39 – Indicator lights do not light up. (Except Turn, Hi–beam and security) 1. GAUGE Fuse 2. Wire Harness – – 2001 PRIUS (RM778U) Author: Date: 1674 BE–8 BODY ELECTRICAL – TROUBLESHOOTING Shift position indicator light does not light up. 1. 2. 3. 4. 5. ECM Shift Position Sensor HV ECU Meter Circuit Plate Wire Harness – HT–54 – BE–39 – CRUISE indicator light does not light up. 1. 2. 3. 4. Bulb HV ECU Meter Circuit Plate Wire Harness – – BE–39 – DEFOGGER SYSTEM This system uses the multiplex communication system, so check diagnosis system of the multiplex communication system before you proceed with troubleshooting. Symptom Suspect Area See page Rear window defogger does not operate. 1. 2. 3. 4. 5. 6. 7. 8. DEF M–Fuse Defogger Relay Defogger Switch (in A/C Amplifier) Defogger Wire Wire Harness Body ECU Noise Filter A/C ECU BE–12 BE–49 DI–864 BE–49 – DI–678 – DI–864 Mirror heater does not operate. 1. 2. 3. 4. M–HTR Fuse (Passenger SIde J/B) Mirror Heater Relay Mirror Heater Wire Harness BE–12 BE–49 BE–49 – POWER WINDOW CONTROL SYSTEM This system uses the multiplex communication system, so check diagnosis system of the multiplex communication system before you proceed with troubleshooting. Symptom Suspect Area See page Power window dose not operate. 1. 2. 3. 4. 5. 6. 7. ECU B Fuse GAUGE Fuse Power Main Relay Ignition Switch Power Window Master Switch Body ECU Wire Harness BE–12 BE–12 BE–56 BE–17 BE–56 DI–678 – Only the driver’s window does not operate. 1. 2. 3. 4. Power Window Master Switch Power Window Switch Power Window Motor Wire Harness BE–56 BE–56 BE–56 – ”Window lock function” does not operate. Power Window Master Switch BE–56 Illumination does not light up. Power Window Master Switch BE–56 2001 PRIUS (RM778U) Author: Date: 1675 BE–9 BODY ELECTRICAL – TROUBLESHOOTING POWER DOOR LOCK CONTROL SYSTEM This system uses the multiplex communication system, so check diagnosis system of the multiplex communication system before you proceed with troubleshooting. Symptom Suspect Area See page All the doors cannot be locked or unlocked. (Power Window Control System is normal.) 1. Door Lock Control Switch 2. Body ECU 3. Wire Harness BE–62 DI–678 – Only one side door lock control does not operate. 1. Door Lock Motor 2. Wire Harness BE–62 – Door key related function does not operate. 1. Door Key Lock and Unlock Switch 2. Body ECU 3. Wire Harness BE–62 DI–678 – Key confinement prevention function does not operate. 1. 2. 3. 4. BE–17 BE–27 DI–678 – Key Unlock Warning Switch Door Courtesy Switch Body ECU Wire Harness THEFT DETERRENT SYSTEM This system uses the multiplex communication system, so check diagnosis system of the multiplex communication system before you proceed with troubleshooting. HINT: Troubleshooting of the theft deterrent system is based on the premise that the door lock control system is operating normally. Accordingly, before troubleshooting the theft deterrent system, first make certain that the door lock control system is operating normally. Symptom Suspect Area See page The theft deterrent system cannot be set 1. 2. 3. 4. 5. 6. 7. Indicator light circuit ECU power source circuit Key unlock warning switch circuit Door key lock and unlock switch circuit Door courtesy switch circuit Door unlock detection switch circuit Engine hood courtesy switch circuit DI–704 DI–685 DI–695 DI–724 DI–714 DI–710 DI–720 The indicator light does not blink when system is set. Indicator light circuit DI–704 When the system is set (The system does not operate when the rear door is unlocked). Door unlock detection switch circuit DI–710 When the system is set (The system does not operate when the luggage compartment door is opened by a method other than the key). Luggage compartment door courtesy switch circuit DI–722 When the system is set (The system does not operate when the engine hood is lifted). Engine hood courtesy switch circuit DI–720 While the system is in warning operation (Horns do not sound). Horn relay circuit DI–697 While the system is in warning operation (Headlights do not flash). Headlight control relay circuit DI–693 While the system is in warning operation (Taillights do not flash). Taillight control relay circuit DI–691 While the system is in warning operation (The door lock is not locked). Door unlock detection switch circuit DI–710 System is still set even when a rear door is open Door courtesy switch circuit DI–714 Even when the system is not set (Horns sound). Horn relay circuit DI–697 2001 PRIUS (RM778U) Author: Date: 1676 BE–10 BODY ELECTRICAL – TROUBLESHOOTING Even when the system is not set (Headlights stay on). Headlight control relay circuit DI–697 Even when the system is not set (Taillights stay on). Taillight control relay circuit DI–691 WIRELESS DOOR LOCK CONTROL SYSTEM This system uses the multiplex communication system, so check diagnosis system of the multiplex communication system before you proceed with troubleshooting. HINT:  Troubleshooting of the wireless door lock control system is based on the premise that the door lock control system is operating normally. Accordingly, before troubleshooting the wireless door lock control system, first make certain that the door lock control system is operating normally.  If the trouble still reappears even though there are no abnormalities in any of the other circuits, then check and replace the Wireless Door Lock Control Receiver as the last step. Symptom All functions of wireless door lock control system do not operate. Suspect Area 1. 2. 3. 4. See page Transmitter Wireless Door Lock Control Receiver Wire Harness Body ECU BE–83 BE–83 – DI–678 POWER MIRROR CONTROL SYSTEM Symptom Suspect Area See page Both right and left mirrors do not operate. 1. 2. 3. 4. ACC Fuse ACC Relay Mirror Switch Wire Harness BE–12 BE–12 BE–93 – Only one side of mirror does not operate. 1. Mirror Motor 2. Wire Harness BE–93 – AUDIO SYSTEM Symptom Audio system abnormal operation. Suspect Area See page TROUBLESHOOTING BE–97 CLOCK SYSTEM Symptom Suspect Area See page Clock will not operate. TROUBLESHOOTING NO.1 BE–102 Clock loses or gains time. TROUBLESHOOTING NO.2 BE–102 HYBRID BEHICLE IMMOBILIZER SYSTEM Symptom Hybrid vehicle immobilizer system does not operate. Suspect Area See page Pre–check BE–111 2001 PRIUS (RM778U) Author: Date: 1677 BE–11 BODY ELECTRICAL – TROUBLESHOOTING HORN SYSTEM Symptom Suspect Area See page Horn system does not operate. 1. 2. 3. 4. 5. HORN Fuse Horn Relay Horn Switch Horn Wire Harness BE–12 BE–117 BE–117 BE–117 – Horns blow all the time. 1. Horn Relay 2. Horn Switch 3. Wire Harness BE–117 BE–117 – One horn operates but the other horn does not operate. 1. Horn 2. Wire Harness BE–117 – Horns operate abnormally. 1. Horn Relay 2. Horn 3. Wire Harness BE–117 BE–117 – 2001 PRIUS (RM778U) Author: Date: 1678 BE–12 BODY ELECTRICAL – POWER SOURCE POWER SOURCE BE1UY–02 LOCATION No. 2 Relay Block No. 3 Relay Block Engine Room J/B Instrument Panel J/B I18844 2001 PRIUS (RM778U) Author: Date: 1679 BE–13 BODY ELECTRICAL – POWER SOURCE Engine room J/B: K 18 J 17 I 16 15 H G E D F 14 13 12 11 10 9 8 7 6 5 4 Fuses: 1. HTR Fuse 2. RDI Fuse 3. ABS No. 2 Fuse 4. CDS FAN Fuse 5. HORN Fuse 6. THRO Fuse 7. ABS No. 3 Fuse 8. TURN–HAZ Fuse 9. AM2 Fuse 10. BATT FAN B C 3 A 2 1 Relays: 11. DOME Fuse 12. HEAD HI (RH) Fuse *1 13. HEAD HI (LH) Fuse *1 14. HEAD LO (LH) *1 HEAD (LH) *2 15. HEAD LO (RH) *1 HEAD (RH) *2 16. EFI Fuse 17. HEV Fuse 18. HEAD Fuse *1 A. FAN NO. 1 Relay B. FAN NO. 2 Relay C. FAN NO. 3 Relay D. IG2 Relay E. HORN Relay F. HTR Relay G. EFI Relay H. CLR MG Relay I. HEAD Relay J. CIR OPN Relay K. DIM Relay *1 *1: w/ Daytime Running Light *2: w/o Daytime Running Light I17787 2001 PRIUS (RM778U) Author: Date: 1680 BE–14 BODY ELECTRICAL – POWER SOURCE Instrument Panel J/B: 18 A C 17 B 12 8 1 13 9 2 14 10 3 15 11 4 16 5 D 6 7 E Fuses: 1. HTR Fuse 2. STOP Fuse 3. ECU–B Fuse 4. DOOR Fuse 5. OBDII Fuse 6. PWR1 Fuse 7. AM1 Fuse Relays: 8. GAUGE Fuse 9. ECU–IG Fuse 10. WIPER Fuse 11. WASHER Fuse 12. PANEL Fuse 13. TAIL Fuse 14. ACC Fuse 15. CIG Fuse 16. SRS ACC Fuse 17. PWR Fuse 18 DEF Fuse A. IG1 Relay B. ACC Relay C. TAIL Relay D. POWER Relay E. DEF Relay I17788 2001 PRIUS (RM778U) Author: Date: 1681 BE–15 BODY ELECTRICAL – POWER SOURCE Engine Room R/B No. 3: 6 5 3 4 B C H 2 1 A G 7 E Fuses: D Relays: 1. HTR2 Fuse 2. HTR1 Fuse 3. ABS No. 4 Fuse 4. ABS No. 1 Fuse 5. EMPS Fuse 6. HTR3 Fuse 7. DRL Fuse A. A/C W/P Relay B. ABS SOL Relay C. DRL Relay D. HTR2 Relay E. HTR1 Relay G. HTR3 Relay H. EPMS Relay Engine Room R/B No. 2: C B A Relays: A. IGCT Relay B. HYDRO MTR No. 2 Relay C. HYDRO MTR No. 1 Relay I17789 2001 PRIUS (RM778U) Author: Date: 1682 BE–20 BODY ELECTRICAL – HEADLIGHT AND TAILLIGHT SYSTEM BE1UX–02 INSPECTION 1. HI HEAD LO TAIL OFF Switch position Tester connection Specified condition OFF – TAIL 14 – 16 Continuity HEAD 13 – 14 – 16 Continuity No continuity If continuity is not as specified, replace the switch. 2. INSPECT HEADLIGHT DIMMER SWITCH CONTINUITY Flash 7 8 INSPECT LIGHT CONTROL SWITCH CONTINUITY Switch position Tester connection Specified condition Low beam 16 – 17 Continuity High beam 7 – 16 Continuity Flash 7 – 8 – 16 Continuity If continuity is not as specified, replace the switch. 17 13 16 14 I14295 3. 1 2 5 3 3 1 5 2 INSPECT HEADLIGHT CONTROL RELAY CONTINUITY Condition Tester connection Specified condition Constant 1–3 Continuity Apply B+ between terminals 1 and 2. 2–5 Continuity If continuity is not as specified, replace the relay. Z05930 4. 1 2 3 5 5 2 1 3 INSPECT TAILLIGHT CONTROL RELAY CONTINUITY Condition Tester connection Specified condition Constant 1–2 Continuity Apply B+ between terminals 1 and 2. 3–5 Continuity If continuity is not as specified, replace the relay. N14863 5. 2 3 1 5 3 1 5 2 Condition Tester connection Specified condition Constant 1–3 Continuity Apply B+ between terminals 1 and 2. 2–5 Continuity If continuity is not as specified, replace the relay. Z05930 2001 PRIUS (RM778U) INSPECT DRL RELAY CONTINUITY BE–21 BODY ELECTRICAL HEADLIGHT AND TAILLIGHT SYSTEM 6. INSPECT DAYTIME RUNNING LIGHT MAIN RELAY CIRCUIT Disconnect the connector from the relay and inspect the connector on the wire harness side. Wire Harness Side h–10–1–A – I17862 Tester connection Condition Specified condition 2 – Ground Constant Continuity 3 – Ground Constant Battery voltage 4 – Ground Terminal 5 ground Battery voltage 6 – Ground Constant Battery voltage 7 – Ground Light control switch OFF or TAIL No continuity 7 – Ground Light control switch HEAD Continuity 8 – Ground Headlight dimmer switch FLASH or HI Continuity 9 – Ground Engine running Battery voltage 12 – Ground Ignition switch OFF No voltage 12 – Ground Ignition switch ON Battery voltage If circuit is specified, try replacing the relay with a new one. If circuit is not as specified, inspect the circuits connected to other parts. 2001 PRIUS (RM778U) BE–22 BODY ELECTRICAL – HEADLIGHT AND TAILLIGHT SYSTEM BE1CY–05 ADJUSTMENT For Adjustment in Vertical Direction I23044 2001 PRIUS (RM778U) BE–23 BODY ELECTRICAL 29.7 mm (1.17 in.) 7 4 H 0.4 ° 3 m (9.84 ft) V RH Line 90 ° W V LH Line Low Beam: 6 5 6 V LH Line V Line V RH Line H 4 29.7 mm (1.17 in.) High Beam: W 7 29.7 mm 6 6 (1.17 in.) 5 V LH Line V Line V RH Line 4 H W O: step No. 2001 PRIUS (RM778U) 29.7 mm (1.17 in.) I17791 – HEADLIGHT AND TAILLIGHT SYSTEM ADJUST HEADLIGHT AIM ONLY (a) Place the vehicle in the following conditions.
The area around the headlight is not deformed.
The vehicle is parked on a level surface.
Tire inflation pressure is the specified value.
A driver is in the driver’s seat and the vehicle is in a state ready for driving (with a tank full).
The vehicle has been bounced several times. (b) Check the headlight aiming. (1) Prepare a thick white paper. (2) Stand the paper perpendicular to the ground at the position 9.84 ft away from the headlights. (3) Ensure that the center line of the vehicle and the paper face forms a 90–degree angle as shown in the illustration. (4) Draw a horizontal line (H line) on the paper, showing where the headlights should strike. (5) Draw a vertical line (V line) to where the center line of the vehicle is to be. (6) Draw 2 vertical lines (by connecting the low and high beam center marks) to where the both headlights should strike (V RH and V LH lines). (7) Draw a horizontal line (by connecting the both low beam center marks) to where the headlights should strike (H RH and H LH lines). (8) Start the engine. (9) Turn the headlights ON. (10) Check that the headlights properly strike the position shown in the illustration. (11) If not, adjust the lights in the vertical direction. HINT: As shown in the illustration, adjust each aim of the RH and LH lights. (c) When adjusting it in the vertical direction: Using adjusting bolt, adjust the headlight aim to within the specified range. BE–27 BODY ELECTRICAL – INTERIOR LIGHT SYSTEM BE1V0–02 INSPECTION 1. INSPECT FRONT PERSONAL LIGHT CONTINUITY Using an ohmmeter, check that continuity exists between terminals. If continuity is not as specified, replace the light assembly or bulb. I17855 2. (a) (b) INSPECT INTERIOR LIGHT CONTINUITY Disconnect the connector from the room light. Turn the room light switch ON, check that continuity exists between terminal 1 and body ground. If continuity is not as specified, replace the light assembly or bulb. 2 I14261 3. (a) INSPECT DOOR COURTESY SWITCH CONTINUITY Check that continuity exists between terminals and the switch body with the switch ON (Switch pin released: opened door). (b) Check that no continuity exists between terminals and the switch body with the switch OFF (Switch pin pushed in: closed door). If operation is not as specified, replace the switch. ON OFF I14287 4. INSPECT LICENCE PLATE LIGHT CONTINUITY Using an ohmmeter, check that continuity exists between terminals. If continuity is not as specified, replace the light assembly or bulb. I11720 5. ON OFF I01267 2001 PRIUS (RM778U) INSPECT LUGGAGE COMPARTMENT DOOR COURTESY SWITCH CONTINUITY (a) Check that continuity exists between terminals and the switch body with the switch ON (Switch pin released: opened door). (b) Check that no continuity exists between terminals and the switch body with the switch OFF (Switch pin pushed in: closed door). If operation is not as specified, replace the switch. BE–28 BODY ELECTRICAL 6. 2 INTERIOR LIGHT SYSTEM INSPECT LUGGAGE COMPARTMENT LIGHT CONTINUITY Using an ohmmeter, check that continuity exists between terminals. If continuity is not as specified, replace the light assembly or bulb. 1 I01268 2001 PRIUS (RM778U) – BE–34 BODY ELECTRICAL – WIPER AND WASHER SYSTEM BE1V1–01 INSPECTION 1. HI LO Washer ON 8 17 7 INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY Switch position Tester connection Specified condition INT OFF 7 – 16 Continuity MIST INT 7 – 16 Continuity OFF LO 7 – 17 Continuity HI 8 – 17 Continuity Washer ON 2 – 11 Continuity If continuity is not as specified, replace the switch. 2 11 16 I14298 2. 7 2 (a) (b) (c) (d) 16 I01313 (e) 7 17 2 INSPECT FRONT WIPER INTERMITTENT OPERATION Turn the wiper switch to INT position. Turn the intermittent time control switch to FAST position. Connect the positive (+) lead from the battery to terminal 16 and the negative (–) lead to terminal 2. Connect the positive (+) lead from the voltmeter to terminal 7 and the negative (–) lead to terminal 2, check that the meter needle indicates battery voltage. After connecting terminal 16 to terminal 17, connect to terminal 2 to terminal 17, check the voltage rises from 0 volts to battery voltage with in the times, as shown in the table. INT time control switch position Voltage Approx. 1 ∼ 3 sec. 16 I01314 FAST Battery voltage 0 Volt Approx. 10 ∼ 15 secs. SLOW Battery voltage 0 Volt If operation is not as specified, replace the wiper and washer switch. 2001 PRIUS (RM778U) BE–35 BODY ELECTRICAL 7 3. (a) 2 (b) (c) – WIPER AND WASHER SYSTEM INSPECT FRONT WASHER LINKED OPERATION Connect the positive (+) lead from the battery to terminal 16 and the negative (–) lead to terminal 2. Connect the positive (+) lead from the voltmeter to terminal 7 and the negative (–) lead to terminal 2. Push in the washer switch, and check that the voltage changes, as shown in the table. 16 I01313 Washer Switch ON OFF Less than 1 sec. Approx. 3 secs. Battery voltage 0 Volt If operation is not as specified, replace the wiper and washer switch. 5 4. Low Speed: INSPECT FRONT WIPER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 5 and the negative (–) lead to terminal 4, check that the motor operates at low speed. If operation is not as specified, replace the motor. 4 I11672 5. 3 High Speed: INSPECT FRONT WIPER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 3 and the negative (–) lead to terminal 4, check that the motor operates at high speed. If operation is not as specified, replace the motor. 4 I11673 5 6. 4 (a) I11674 2001 PRIUS (RM778U) Stopping at Stop Position: INSPECT FRONT WIPER MOTOR OPERATION Operate the motor at low speed and stop the motor operation anywhere except at the stop position by disconnecting positive (+) lead from terminal 5. BE–36 BODY ELECTRICAL 2 5 (b) (c) WIPER AND WASHER SYSTEM Connect terminals 1 and 5. Connect the positive (+) lead from the battery to terminal 2 and negative (–) lead to terminal 4, check that the motor stops running at the stop position after the motor operates again. If operation is not as specified, replace the motor. 1 4 I11675 2001 PRIUS (RM778U) – BE–37 BODY ELECTRICAL – COMBINATION METER COMBINATION METER BE1VS–02 LOCATION Brake Master Cylinder
Brake Fluid Level Warning Switch Engine Room J/B
DOME Fuse Combination Meter Assembly
Meter Circuit Multi Display Occupant Detection Sensor Instrument Panel J/B
Body ECU
GAUGE Fuse Stop Light Switch Ignition Switch Seat Belt Buckle Switch I18849 2001 PRIUS (RM778U) Author: Date: 1704 BE–38 BODY ELECTRICAL – COMBINATION METER Door Courtesy Switch Fuel Sender Gauge I17784 2001 PRIUS (RM778U) Author: Date: 1705 BE–39 BODY ELECTRICAL – COMBINATION METER BE1VT–02 CIRCUIT Connector ”B” Connector ”A” I19092 2001 PRIUS (RM778U) BE–40 BODY ELECTRICAL – COMBINATION METER A20 A12 A14 A2 A3 A1 Conversion (VFD) Drive unit ECU Correspon dence A13 Buzzer A22 A21 B7 B6 B1 A9 A11 Power Supply Circuit Drive unit B2 B3 Open door indicator Illumination Brake warning Driver seat belt warning Low oil pressure warning Discharge warning Output control indicator CRUISE main indicator Engine coolant warning (Low) Engine coolant warning (High) Passenger seat belt warning Malfunction indicator B4 A10 ABS warning A16 B5 SRS warning Left turn indicator A19 A18 A17 Right turn indicator A15 Hi–beam indicator I17798 2001 PRIUS (RM778U) BE–41 BODY ELECTRICAL No. A – Wiring connector side 1 ODO/TRIP switch (TC) 2 3 ODO/TRIP switch (E) ODO/TRIP switch (ODO) 9 10 11 ABS ECU (SI) ABS ECU (ABS) EMPS ECU 12 13 Fuel tank temperature (+) Hybrid vehicle control ECU (4P) 14 15 16 17 Ground Ground Center airbag sensor assembly Headlight dimmer switch 18 19 Turn signal switch (Right) Turn signal switch (Left) 20 21 Fuel tank temperature (–) DOME Fuse 22 GAUGE Fuse B 2001 PRIUS (RM778U) 1 Back–up light relay 2 3 4 5 6 7 Body ECU Body ECU Engine ECM ACC Fuse Light control rheostat (TC) Light control rheostat (TR) COMBINATION METER BE–42 BODY ELECTRICAL – COMBINATION METER BE1VU–02 INSPECTION 1. INSPECT COMBINATION METER CIRCUIT Disconnect connector ”A” and ”B” from the combination meter and inspect the connectors on the wire harness side as shown in the table. Connector ”A” Connector ”B” I17803 Tester connection Condition Specified condition A1 – Ground (ILL – Body ground) Ignition switch ON and tail cancel switch ON or OFF Below 1V or 4.5 – 5.5 V A2 – Ground (E – Body ground) Constant Continuity A3 – Ground (OPO – Body ground) Ignition switch ON and trip reset switch ON or OFF Below 1V or 4.5 – 5.5 V A9 – Ground (SI – Body ground) Ignition switch ON and slowly turn drive wheel Below 1V or 10 – 14 V A10 – Ground (LP – Body ground) Ignition switch ON and ABS indicator ON or OFF Below 1V or 10 – 14 V A11 – Ground (L – Body ground) Ignition switch ON Pulse generation A13 – Ground (+S – Body ground) I iti switch Ignition it h ON and d slowly l l turn t drive d i wheel h l A14 – Ground (ES – Body ground) Constant Continuity A15 – Ground (EP – Body ground) Constant Continuity A16 – Ground (SW – Body ground) Ignition switch ON and air bag indicator light ON or OFF Below 1V or 10 – 14 V A17 – Ground (S – Body ground) Headlight dimmer switch Hi or Low Below 1V or 10 – 14 V A18 – Ground (B – Body ground) Ignition switch ON and turn signal switch right Below 1V or 10 – 14 V A19 – Ground (B – Body ground) Ignition switch ON and turn signal switch left Below 1V or 10 – 14 V A21 – Ground (B – Body ground) Constant 10 – 14 V 2001 PRIUS (RM778U) Below 1V or 10 – 14 V Below 1V or 4.5 – 5.5 V BE–43 BODY ELECTRICAL – COMBINATION METER A22 – Ground (IG – Body ground) Ignition switch OFF or ON Below 1V or 10 – 14 V B1 – Ground (ROUT – Body ground) Ignition switch ON and shift lever position is ”R” or except ”R” Below 1V or 10 – 14 V B2 – Ground (MPX+ – Body ground) Ignition switch ON Pulse generation B3 – Ground (MPX – Body ground) Ignition switch ON Pulse generation B5 – Ground (ACC – Body ground) Ignition switch ACC 10 – 14 V 2. INSPECT SPEEDOMETER ON–VEHICLE Using a speedometer tester, inspect the speedometer for allowable indication error and check the operation of the odometer. HINT: Tire wear and tire over or under inflation will increase the indication error. If error is excessive, replace the speedometer. (mph) (km/h) Standard indication Allowable range Standard indication Allowable range 20 18– 22 20 18 – 22 40 38 – 42 40 38 – 42 60 59 – 63 60 58 – 62 80 79 – 83 80 78 – 82 100 99 – 104 100 97 – 103 120 119 – 125 120 117 – 123 140 137 – 143 160 157 – 163 3. INSPECT INPUT SPEED SIGNAL While driving the vehicle at 10 km/h, measure the voltage between connector terminals A9 and A14 of the combination meter. Standard: Change between Hi and LO is repeated 7 time for 1 second. HINT: Check it the ignition switch ON and the connector connected. I18205 4. INSPECT OUTPUT SPEED SIGNAL While driving the vehicle at 10 km/h, measure the voltage between connector terminal A13 and A14 of the combination meter. Standard: Change between Hi and LO is repeated 7 time for 1 second. HINT: Check it the ignition switch ON and the connector connected. I18205 2001 PRIUS (RM778U) BE–44 BODY ELECTRICAL – COMBINATION METER 5. INSPECT FUEL SENDER GAUGE VOLTAGE Measure the voltage between terminals 1 and 6 for each fuel level. HINT: The fuel sender gauge cannot be removed. As the resistance value changes according to the remaining fuel amount, refer to the above standard value. Fuel Sender Gauge Connector I17865 Fuel level Resistance (Ω) Full Approx. 430 Half Approx. 1000 – 2000 Empty Approx. 5000 If resistance value is not as specified, replace the fuel tank. If resistance value is as specified, replace the combination meter. 6. INSPECT TEMPERATURE SENDER RESISTANCE Measure the resistance between terminal 4 and 8 If the resistance value is not in the following area, replace fuel tank. 1.5 – 100 (Ω) at 0 – 30°C Fuel Sender Gauge Connector I17865 Ignition Switch 7. (a) INSPECT LOW OIL PRESSURE WARNING LIGHT Disconnect the connector from the warning switch and ground terminal of the wire harness side connector. (b) Turn the ignition switch ON, check that the warning light lights up. If the warning light does not light up, test the bulb or inspect wire harness. Warning Light Wire Harness Side Battery 1 I01277 8. (a) (b) INSPECT LOW OIL PRESSURE SWITCH CONTINUITY Check that continuity exists between terminal and ground with the engine stopped. Check that no continuity exists between terminal and ground with the engine running. HINT: Oil pressure should be over 24.5 kPa (0.25 kgf/cm2, 3.55 psi) If operation is not as specified, replace the switch. I01278 2001 PRIUS (RM778U) BE–45 BODY ELECTRICAL – COMBINATION METER 9. (a) INSPECT BRAKE WARNING SYSTEM LIGHT Disconnect the connector from the brake fluid warning switch. (b) Connect terminals of the wire harness side of the level warning switch connector. (c) Start the engine, check that the warning light lights up. If the warning light does not light up, test the bulb or wire harness. Warning Light Ignition Switch Battery BE1217 10. I11650 INSPECT BRAKE FLUID LEVEL WARNING SWITCH CONTINUITY (a) Remove the reservoir tank cap and strainer. (b) Disconnect the connector. (c) Check that no continuity exists between terminals with the switch OFF (float up). (d) Use syphon, etc. to take fluid out of the reservoir tank. (e) Check that continuity exists between terminals with the switch ON (float down). (f) Pour the fluid back in the reservoir tank. If operation is not as specified, replace the switch. 11. INSPECT PARKING BRAKE WARNING LIGHT (a) Disconnect the connector from the parking brake switch. (b) Ground terminal of the wire harness side connector. (c) Start the engine, check that the warning light lights up. If the warning light does not light up, test the bulb or inspect wire harness. Warning Light Ignition Switch Battery BE0044 12. (a) INSPECT PARKING BRAKE SWITCH CONTINUITY Check that continuity exists between terminal and switch body with the switch ON (switch pin released). (b) Check that no continuity exists between terminal and switch body with the switch OFF (switch pin pushed in). If operation is not as specified, replace the switch or inspect ground point. Z11183 2001 PRIUS (RM778U) BE–46 BODY ELECTRICAL COMBINATION METER 13. INSPECT OPEN DOOR WARNING LIGHT Disconnect the connector from the door courtesy switch, and ground terminal 1 of the wire harness side connector and check that the warning light lights up. If the warning light does not light up, inspect the bulb or wire harness. Warning Light Ignition Switch Battery BE0044 2001 PRIUS (RM778U) – BE–49 BODY ELECTRICAL – DEFOGGER SYSTEM BE1D5–03 7 1 8 INSPECTION 1. (a) INSPECT DEFOGGER TIMER OPERATION Connect the positive (+) lead from the battery to terminal 1, 8 and negative (–) lead to terminal 7. (b) Connect the positive (+) lead from the battery to terminal 5 through a 3.4 W test bulb. (c) Turn the defogger switch ON and check that the indicator light and test bulb light up for 12 for 18 minutes, then the indicator light and test bulb lights go out. If operation is not as specified, inspect the A/C amplifier. I17792 2. INSPECT DEFOGGER SWITCH CIRCUIT Connector disconnected: Disconnect the connector from the switch and inspect the connector on wire harness side, as shown in the chart. I17793 Tester connection Condition Specified condition 1 – Ground Ignition switch LOCK or ACC No voltage 1 – Ground Ignition switch ON Battery positive voltage 7 – Ground Constant Continuity 8 – Ground Constant Battery positive voltage If the circuit is not as specified, replace the switch. 3. 1 2 3 5 5 1 2 3 I01200 2001 PRIUS (RM778U) INSPECT DEFOGGER RELAY CONTINUITY Condition Tester connection Specified condition Constant 1–2 Continuity Apply B+ between terminals 1 and 2. 3–5 Continuity If continuity is not as specified, replace the relay. BE–50 BODY ELECTRICAL – DEFOGGER SYSTEM 4. INSPECT DEFOGGER WIRE NOTICE:
Tester Probe Heat WIre
Tin Foil
I01291 (a) (b) (c) At Center When cleaning the glass, use a soft, dry cloth, and wipe the glass in the direction of the wire. Take care not to damage the wires. Do not use detergents or glass cleaners with abrasive ingredients. When measuring voltage, wind a piece of tin foil around the top of the negative probe and press the foil against the wire with your finger, as shown. Turn the ignition switch ON. Turn the defogger switch ON. Inspect the voltage at the center of each heat wire, as shown. Voltage Criteria Approx. 5V Okay (No break in wire) Approx. 10V or 0V Broken wire I01292 0 Volts Several Volts Broken Wire I01293 2001 PRIUS (RM778U) HINT: If there is approximately 10 V, the wire is broken between the center of the wire and the positive (+) end. If there is no voltage, the wire is broken between the center of the wire and ground. (d) Place the voltmeter positive (+) lead against the defogger positive (+) terminal. (e) Place the voltmeter negative (–) lead with the foil strip against the heat wire at the positive (+) terminal end and slide it toward the negative (–) terminal end. (f) The point where the voltmeter deflects from zero to several V is the place where the heat wire is broken. HINT: If the heat wire is not broken, the voltmeter indicates 0 V at the positive (+) end of the heat wire but gradually increases to about 12 V as the meter probe is moved to the other end. BE–51 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM BE1V2–01 POWER WINDOW CONTROL SYSTEM TROUBLESHOOTING Power WIndow Master Switch I17845 1 One touch power window does not move up and down. After turning the ignition switch ON and power window master switch UP or DOWN on the drivers side, check that the master switch AUTO light blinks.
Error is classified into the following 3 types according to the way of blinking. ON UP or DOWN OFF 1 Limit switch error 3 Limit switch/Pulse sensor synchronize error Repeat 1.5 secs. 0.5 sec. 0.5 sec. 1.5 secs. 0.5 sec. 2 secs. 2 Pulse sensor error 2.5 secs. 4 secs. 0.5 sec. 3.5secs. 4 secs. Repeat 0.5 secs. Repeat 1 sec. < Reference >
When the ignition switch is turned OFF after the AUTO light starts blinking, the blinking will stop 43 sec. later.
When the ignition switch is turned ON after that, the AUTO light will start blinking again. Blinks in the 1 way No Remove the master switch. (Connector connection condition) Master switch defective Blinks in the 2 or 3 way CONTINUED ON NEXT PAGE CONTINUED ON NEXT PAGE 2001 PRIUS (RM778U) Author: Date: 1718 BE–52 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM CONTINUED FROM PREVIOUS PAGE CONTINUED FROM PREVIOUS PAGE Open the fully closed window glass of the driver’s door and check the change of the voltage between terminal 13 and 11 of the master switch Fully opened: 0 V Fully closed: 10 – 14 V NG Disconnect the connecters of master switch and driver’s power window motor. OK Master switch defective Does continuity exist between connector terminals on the vehicle side? Master switch side ↔ Motor side 12 (PLS) terminal ↔ 3 terminal 13 (LMT) terminal ↔ 4 terminal 11 (SGNG) terminal ↔ 5 terminal No Yes Wire harness defective (open) Does continuity exist between 11, 12, and 13 terminals on the master switch side or 3, 4, and 5 terminals on the motor side and body ground? Yes No Wire harness defective (short) Connect the connector of power window motor. Yes Connect the normal master switch, do AUTO UP and AUTO DOWN operations work? No Power window motor defective. 2001 PRIUS (RM778U) Author: Date: 1719 BE–53 BODY ELECTRICAL 2 – POWER WINDOW CONTROL SYSTEM During AUTO UP operation, the power window moves down. When operating AUTO UP with the ignition switch ON, is there a cause of increasing friction resistance at the inverse position? Yes Disassemble the door and repair or replace the applicable part. No Check and replace door glass run. No Power window regulator defective. No Power window motor defective. No Remove the power window regulator assembly. Does the window operate smoothly when moving the window up manually after assembling? Yes Remove the power window motor from the power window regulator assembly. When operating the power window regulator manually, does the regulator move smoothly? Are gears not damaged? Yes Does window motor rotate smoothly? Yes Reset the limit switch (See page BE–60). Does the window move normally? Yes Normal (Check the function) No Master switch defective. 2001 PRIUS (RM778U) Author: Date: 1720 BE–54 BODY ELECTRICAL 3 – POWER WINDOW CONTROL SYSTEM The DOWN function does not work though some other objects are caught in the power window glass. Is the system in the jam protection function operating condition?
The AUTO UP operation works with the ignition switch ON. (One–touch operation) No Normal (Perform function check) Yes Does the AUTO UP or AUTO DOWN operation work with the ignition switch ON? No Proceed to chart 1. Yes Is the power window within the jam protection function operating area? < Out of the operating area > Area around the fully closed position Yes No Reset the limit switch (See page BE–60). Does the power window operate normally? Yes Normal After performing operation check repeatedly, conduct the function check. No Master switch defective. 2001 PRIUS (RM778U) Author: Date: 1721 BE–56 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM BE1V3–02 INSPECTION 1. (a) (b) (c) (d) 1 (e) INSPECT ONE TOUCH POWER WINDOW SYSTEM/ CURRENT OF CIRCUIT (Using an ammeter) Disconnect the connector from the master switch. Connect the positive (+) lead from the ammeter to terminal 1 on the wire harness side connector and the negative (–) lead to negative (–) terminal of the battery. Connect the positive (+) lead from the battery to terminal 2 on the wire harness side connector. As the window goes down, check that the current flow is approximately 7 A. Check that the current increases up to approximately 14.5 A or more when the window stops going down. HINT: The PTC opens some 4 – 90 seconds after the window stops going down, so that check must be made before the PTC operates. If the operation is as specified, replace the master switch. 2 I17796 2. (a) (b) (c) (d) (e) INSPECT ONE TOUCH POWER WINDOW SYSTEM/ CURRENT OF CIRCUIT (Using an ammeter with a current–measuring probe) Remove the driver door ECU with connectors connected. Attach a current–measuring probe to terminal 5 of the wire harness. Turn the ignition switch ON and set the power window switch in the down position. As the window goes down, check that the current flow is approximately 7 A. Check that the current increases up to approximately 14.5 A or more when the window stops going down. HINT: The PTC opens some 4 – 90 seconds after the window stops going down, so that check must be made before the PTC operates. If operation is as specified, replace the driver door ECU. 5 I17797 3. INSPECT POWER WINDOW SWITCH CONTINUITY Switch position Tester connection UP 2 – 3, 4 – 5 OFF 2–3–5 DOWN 2 – 4, 3 – 5 Specified condition Continuity No continuity Continuity If continuity is not as specified, replace the switch. 4. INSPECT POWER WINDOW SWITCH CIRCUIT (See page DI–726) I08152 2001 PRIUS (RM778U) BE–57 BODY ELECTRICAL 5. 1 3 5 2 2 1 5 3 – POWER WINDOW CONTROL SYSTEM INSPECT POWER MAIN RELAY CONTINUITY Condition Tester connection Specified condition Constant 1–2 Continuity Apply B+ between terminals 1 and 2. 3–5 Continuity If continuity is not as specified, replace the relay. Z05930 6. (a) 1 2 Driver’s door: INSPECT POWER WINDOW MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, check that the motor turns clockwise. I15351 (b) Reverse the polarity, check that the motor turns counterclockwise. If operation is not as specified, replace the motor. NOTICE: Since the jam protection may not work properly be sure to conduct procedures described in ”HOW TO RESET POWER MOTOR (RESET AND PULSE SWITCH)” after this inspection. 1 2 I15352 7. (a) 2 1 Passenger ’s door and rear right door: INSPECT POWER WINDOW MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, check that the motor turns clockwise. I15353 (b) Reverse the polarity, check that the motor turns counterclockwise. If operation is not as specified, replace the motor. 2 1 2001 PRIUS (RM778U) I15354 BE–58 BODY ELECTRICAL 8. (a) 2 1 – POWER WINDOW CONTROL SYSTEM Rear left door: INSPECT POWER WINDOW MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, check that the motor turns clockwise. I15357 (b) Reverse the polarity, check that the motor turns counterclockwise. If operation is not as specified, replace the motor. 2 1 I15358 9. 1 2 I14317 Driver’s door: INSPECT PTC OPERATION (a) Disconnect the connector from the window motor. (b) Connect the positive (+) lead from the ammeter to terminal 1 of the wire harness side connector and the negative (–) lead to negative terminal of the battery. (c) Connect the positive (+) lead from the battery to terminal 2 of the wire harness side connector, and raise the window to the fully closed position. (d) Continue to apply voltage, check that the current changes from approximately 14 A to less than 1 A within 4 to 90 seconds. (e) Disconnect the leads from terminals. (f) Approximately 90 seconds later, connect the positive (+) lead from the battery to terminal 1 and negative (–) lead to terminal 2, check that the window begins to descend. If operation is not as specified, replace the motor. 1 2 I14318 10. (a) (b) 1 2 I14319 2001 PRIUS (RM778U) (c) Except driver’s door: INSPECT PTC OPERATION Disconnect the connector from the power window switch. Connect the positive (+) lead from the ammeter to terminal 1 of the wire harness side connector and the negative (–) lead to negative terminal of the battery. Connect the positive (+) lead from the battery to terminal 2 of the wire harness side connector, and raise the window to the fully closed position. BE–59 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM (d) 2 1 I14320 Continue to apply voltage, check that the current changes from approximately 14 A to less than 1 A within 4 to 90 seconds. (e) Disconnect the leads from terminals. (f) Approximately 90 seconds later, connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, check that the window begins to descend. If operation is not as specified, replace the motor. 11. INSPECT JAM PROTECTION FUNCTION NOTICE: Never, ever be caught any part of your body when checking. HINT: In case of performing resetting of the limit switch, do checking after repeating up and down of the glass with automatic operation. (a) Confirmation of AUTO up operation: Confirm that the window will be fully close with AUTO up operation. (b) Checking of the operation of the jam protection function: (1) Move up the window with AUTO up operation and check that the window will go down when it touches the handle of the hammer stetted. (2) Confirm that the window will then stop going down about 200 mm. HINT: In case of removing the glass, glass guide, regulator and etc. be sure to perform checking of the jam protection function. If the jam protection is not function properly, adjust power window motor reset switch and pulse switch. 2001 PRIUS (RM778U) BE–62 BODY ELECTRICAL – POWER DOOR LOCK CONTROL SYSTEM BE1W7–01 INSPECTION 1. I03147 Switch position Tester connection LOCK 3–6 OFF – UNLOCK 3–5 Specified condition Continuity No continuity Continuity If continuity is not as specified, replace the switch. 2. LOCK UNLOCK INSPECT DOOR LOCK CONTROL SWITCH CONTINUITY Driver’s door: INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY Switch position Tester connection LOCK 3–5 OFF – UNLOCK 3–6 Specified condition Continuity No continuity Continuity If continuity is not as specified, replace the switch. I11689 3. LOCK Passenger ’s door: INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY Switch position Tester connection LOCK 2–4 OFF – UNLOCK 1–4 Specified condition Continuity No continuity Continuity If continuity is not as specified, replace the switch. UNLOCK I11690 4. LOCK UNLOCK I11689 UNLOCK 2001 PRIUS (RM778U) I11690 Switch position Tester connection OFF (Door Lock set to LOCK) – ON (Door Lock set to UNLOCK) 3–4 Specified condition No continuity Continuity If continuity is not as specified, replace the switch. 5. LOCK Driver’s door: INSPECT DOOR UNLOCK DETECTION SWITCH CONTINUITY Passenger ’s door: INSPECT DOOR UNLOCK DETECTION SWITCH CONTINUITY Switch position Tester connection OFF (Door Lock set to LOCK) – ON (Door Lock set to UNLOCK) 3–4 Specified condition No continuity Continuity If continuity is not as specified, replace the switch. BE–63 BODY ELECTRICAL 6. – POWER DOOR LOCK CONTROL SYSTEM Rear left door: INSPECT DOOR UNLOCK DETECTION SWITCH CONTINUITY LOCK Switch position Tester connection OFF – ON 1–2 Specified condition No continuity Continuity If continuity is not as specified, replace the switch. I07301 7. LOCK Rear right door: INSPECT DOOR UNLOCK DETECTION SWITCH CONTINUITY Switch position Tester connection OFF – ON 3–4 Specified condition No continuity Continuity If continuity is not as specified, replace the switch. I07302 8. Driver’s door: INSPECT DOOR LOCK MOTOR OPERATION (a) Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, and check that the door lock link moves to UNLOCK position. (b) Reverse the polarity and check that the door lock link moves to LOCK position. If operation is not as specified, replace the door lock assembly. LOCK UNLOCK UNLOCK 2 LOCK 1 2 1 I14313 2001 PRIUS (RM778U) BE–64 BODY ELECTRICAL – POWER DOOR LOCK CONTROL SYSTEM 9. Passenger ’s door: INSPECT DOOR LOCK MOTOR OPERATION (a) Connect the positive (+) lead from the battery to terminal 5 and the negative (–) lead to terminal 6, and check that the door lock link moves to UNLOCK position. (b) Reverse the polarity and check that the door lock link moves to LOCK position. If operation is not as specified, replace the door lock assembly. LOCK UNLOCK UNLOCK 6 LOCK 5 6 5 I14314 10. Rear left door: INSPECT DOOR LOCK MOTOR OPERATION (a) Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, and check that the door lock link moves to UNLOCK position. (b) Reverse the polarity and check that the door lock link moves to LOCK position. If operation is not as specified, replace the door lock assembly. LOCK UNLOCK LOCK UNLOCK 2 1 2 1 I07299 2001 PRIUS (RM778U) BE–65 BODY ELECTRICAL 11. UNLOCK LOCK UNLOCK 3 4 3 I07300 2001 PRIUS (RM778U) POWER DOOR LOCK CONTROL SYSTEM Rear right door: INSPECT DOOR LOCK MOTOR OPERATION (a) Connect the positive (+) lead from the battery to terminal 3 and the negative (–) lead to terminal 4, and check that the door lock link moves to UNLOCK position. (b) Reverse the polarity and check that the door lock link moves to LOCK position. If operation is not as specified, replace the door lock assembly. LOCK 4 – BE–67 BODY ELECTRICAL – THEFT DETERRENT SYSTEM DI7T9–01 PRE–CHECK 1. OUT LINE OF THEFT DETERRENT SYSTEM When the theft deterrent system detects any theft, it informs people around with flashing lights and sound. This system is designed to be upgraded by featuring an optional glass break sensor. All initial setting are performed in active mode. It can be switched to passive mode by specified operation. (See step 3. CHANGING METHOD OF PASSIVE MODE) HINT: There are 4 conditions in this system which are disarmed state, arming preparation, armed state and alarm sounding. (1) Disarmed state  When the alarming function does not operate.  When theft deterrent function is not performed. (2) Arming preparation  Time until transferring to armed state.  Theft deterrent function is not performed. (3) Armed state When theft deterrent function is possible. (4) Alarm sounding: In this condition, once theft is detected, it is informed using light and sound to people around the vehicle. Refer to the table for alarming method or time. Horn Security horn Headlight Al Alarming i method th d Taillight Hazard Interior light Alarming time 60 seconds Alarming output Continuous 0.4 secs. (ON) 0.4 secs. (OFF) HINT: Alarming output for hazard is same as the one for the hazard on the vehicle. In the arming condition when either of doors is unlocked with key not in the key cylinder, force lock signal is output. 2001 PRIUS (RM778U) BE–68 BODY ELECTRICAL 2. – THEFT DETERRENT SYSTEM ACTIVE ARMING MODE Disarmed state (Key not inserted in ignition.) Perform any of the following and the system will go no to ”Arming preparation”:
With all the doors, engine hood and luggage compartment door closed, lock all doors with the key.
With all the doors, engine hood and luggage compartment door closed, lock all doors with the wireless remote.
With all the doors, engine hood and luggage compartment door closed, open and close any of doors, engine hood or luggage compartment door, then close and lock all doors, engine hood and luggage compartment door. Arming preparation Perform any of the following and the system will return to ”Disarmed state”:
Open any of the doors, engine hood or luggage compartment door.
Unlock any of the doors.
Put the key in the ignition.
Reconnect the battery. Perform the following and the system will go on to ”Armed state”:
Let 30 seconds elapse with all the doors, engine hood and luggage compartment door closed and locked. Armed state Perform any of the following and the system will return to ”Disarmed state”:
Unlock any of the doors or open the luggage compartment door with the wireless remote.
Unlock the doors with the wireless remote.
Put the key in the ignition and turn it to ON. Perform any of the following and the system will go on to ”Alarm sounding”:
Open any of the doors.
Unlock any of the doors in any way other than with a key or the wireless remote.
Open the luggage compartment door in any way other than with a key.
Open the engine hood.
Reconnect the battery.
When input from optional glass break sensor is detected (Dealer option) Alarm sounding Perform any of the following and the system will return to ”Disarmed state”:
Unlock any of the doors or open the luggage compartment door with the wireless remote.
Unlock the doors with the wireless remote.
Put the key in the ignition and turn it to ON. 2001 PRIUS (RM778U) The vehicle’s horn and security horn will sound, and the hazard, interior, tail and head lights flash for 60 seconds. After the alarm has ended, the system will return to ”Armed state”. BE–69 BODY ELECTRICAL – THEFT DETERRENT SYSTEM Indicator light output: Condition Indicator light Disarmed state OFF Arming preparation ON Armed state OFF Alarm sounding ON HINT: Even in disarmed state, the indicator light flash. (Due to the signal output form immobilizer system). The indicator always flashes receiving the signal from the immobilizer system at any time in the armed state. Flashing frequency: 0.2 seconds (ON) 1.8 seconds (OFF) Answer back: The hazard lights flush as answer back under the following conditions. (1) When the system is set. When arming preparation is set from disarmed state using the wireless door lock, the hazard lights flush once. (2) When the system is released. When disarmed state is set from either arming preparation, armed state or alarm sounding using the wireless door lock, the hazard lights flush twice. 2001 PRIUS (RM778U) BE–70 BODY ELECTRICAL 3.   – THEFT DETERRENT SYSTEM PASSIVE ARMING MODE This mode can be switched according to the specified operation. All initially set modes (when shipped from factory) are active mode. (No passive mode) Disarmed state (A) Perform any of the following and the system will go to Disarmed state (B):
Remove the key from the ignition, close the driver’s door, then the ignition OFF. Disarmed state (B) Perform any of the following and the system will return to Disarmed state (A):
Push the unlock switch on the wireless remote.
Put the key in the lock on the driver’s or the passenger door and turn it towards unlock.
Put the key in the ignition.
Reconnect the battery.
Turn the ignition from OFF to ON. Perform any of the following and the system will go to Arming preparation:
Close all the doors, hood and luggage compartment door. Arming preparation Perform any of the following and the system will return to Disarmed state (B):
Open any of the doors, the hood or the luggage compartment door. 2001 PRIUS (RM778U) Perform any of the following and the system will return to Disarmed state (A):
Push the unlock switch on the wireless remote.
Put the key in the lock on the driver’s or the passenger door and turn it towards unlock.
Put the key in the ignition.
Reconnect the battery.
Turn the ignition from OFF to ON. Perform any of the following and the system will go to Armed state:
Allow 30 seconds to elapse with all the doors, hood and luggage compartment door closed. BE–71 BODY ELECTRICAL – THEFT DETERRENT SYSTEM Armed state Perform any of the following and the system will return to Disarmed state (A):
Push the unlock switch on the wireless remote.
Put the key in the lock on the driver’s or the passenger door and turn it towards unlock.
Put the key in the ignition and turn it ON. Perform any of the following and the system will go on to Alarm sounding:
Open any of the doors and allow the entry delay time to pass.
Open the hood.
Open the luggage compartment door with something other than the key or wireless remote.
Reconnect the battery.
Ignition switch is connected directly. Perform any of the following and the system will return to Disarmed state (B):
Open the luggage compartment door with the wireless remote.
Open the luggage compartment door with the Key. Alarm sounding Perform any of the following and the system will return to Armed state:
The alarm sounding period passes. 2001 PRIUS (RM778U) Perform any of the following and the system will return to Disarmed state (A):
Push the unlock switch on the wireless remote.
Put the key in the lock on the driver’s or the passenger door and turn it towards unlock.
Put the key in the ignition and turn it ON. Perform any of the following and the system will return to Disarmed state (B):
Open the luggage compartment door with the wireless remote.
Open the luggage compartment door with the Key. BE–72 BODY ELECTRICAL – THEFT DETERRENT SYSTEM HINT: In armed state either closed door is opened, entry delay occurs. (15 secs.) During this time, the mode transfers to disarmed state when the condition described above * is met. When the condition is not met, the system judges theft occurs, the mode transfers to alarm sounding. Door Close Open Indicator ON OFF Alarming output ON OFF Entry delay time System condition Armed state 2001 PRIUS (RM778U) Alarm sounding BE–73 BODY ELECTRICAL – THEFT DETERRENT SYSTEM Indicator light output: Condition Indicator light Disarmed state OFF Arming preparation ON Armed state (Entry delay time) Alarm sounding OFF (ON) ON HINT: Even in disarmed state, the indicator light flash. (Due to the signal output form immobilizer system). The indicator always flashes receiving the signal from the immobilizer system at any time in the arming condition. Flashing frequency: 0.2 seconds (ON) 1.8 seconds (OFF) (a) Transfer to active mode: In each passive mode, when ”disarmed state of active mode → arming preparation transfer condition” is met, the active mode transfers to each condition. In this case, active mode continues till disarmed state. Passive mode when transfer condition is met. Active mode transfer condition Disarmed state Arming preparation condition Arming preparation condition Arming preparation condition Armed state (During entry delay time) Arming condition (After alarming time has elapsed, arming condition) Alarm sounding After alarming time has elapsed, arming condition (b) 2001 PRIUS (RM778U) Answer back: The hazard lights flush as answer back under the following conditions. (1) When the system is set. When arming preparation is set from disarmed state using the wireless door lock, the hazard lights flush once. (2) When the system is released. When disarmed state is set from either arming preparation, armed state or alarm sounding using the wireless door lock, the hazard lights flush twice. BE–74 BODY ELECTRICAL 4. – THEFT DETERRENT SYSTEM CHANGING METHOD OF PASSIVE MODE (ON or OFF)  No key in ignition key cylinder.  All doors and luggage compartment closed  All doors unlocked  Engine hood open Lock and unlock by or times. remote control 3 Input to the vehicle Output from the vehicle Within 30 secs. Open the driver’s door. Lock and unlock the driver’s door knob 3 times. Within 2 secs. After 2 sec., forced lock functions once. Unlock the driver’s door knob. Close and open the driver’s door 2 times. Within 20 secs. Lock and unlock the driver’s door knob once. Within 2 secs. Afer 2 sec., forced lock functions once. System without passive mode is set. Close and open the driver’s door 3, 4 or 5 times. Lock and unlock the driver’s door knob once. After 2 sec., forced lock functions once. System with passive mode is set. HINT:
Initially (when shipping), system without passive mode is set..
Any input or output other than the above shall be regarded as invalid.(Start again from the beginning). 2001 PRIUS (RM778U) BE–75 BODY ELECTRICAL TOYOTA hand–held tester ECU 5. (a) (b) (c) TOYOTA Break–out–box 2001 PRIUS (RM778U) N09348 – THEFT DETERRENT SYSTEM ECU TERMINAL VALUES MEASUREMENT BY USING TOYOTA BREAK–OUT–BOX AND TOYOTA HAND– HELD TESTER Hook up the TOYOTA break–out–box and TOYOTA hand–held tester to the vehicle. Read the ECU input/output values by following the prompts on the tester screen. Please refer to the TOYOTA hand–held tester has a ”Snapshot” function. This records the measured data and is effective in the diagnosis of intermittent problems. BE–78 BODY ELECTRICAL – WIRELESS DOOR LOCK CONTROL SYSTEM BE0IM–13 PRE–CHECK Only wireless function (Remote control) will not operate. (If a new transmitter or a transmitter of the same type that works properly with the vehicle is not available.) Make the vehicle in the initialized condition: The initialized condition is the condition when the following conditions are satisfied. (1) Key plate has not been inserted in the ignition key cylinder. (2) All the doors are closed. (Door warning light is off.) (3) All the doors are locked. Basic function check: Under the standard operation, when repeating the operation of UNLOCK and LOCK switch 3 times or more alternately, check the UNLOCK–LOCK operation from 3rd time onward.
Following procedures are standard operation. (1) Keep about 1 M away to the right direction from the outside handle of a driver’s seat. (2) Face the transmitter toward the vehicle and press one of transmitter switches for about 1 sec. Yes No 2001 PRIUS (RM778U) Normal
Operative distance may differ according to an operator, the way of holding the transmitter or position.
Because weak electric wave is used, when there is strong wave or noise in the used frequency ,operation distance might be shortened. BE–79 BODY ELECTRICAL – WIRELESS DOOR LOCK CONTROL SYSTEM Transmitter battery check: Yes Replace the transmitter battery with a new or normal one and check UNLOCK–LOCK function works under the standard operation.
The battery should be replaced by only the shops with sufficient skill as new normal battery is necessary.
Battery quality can be judged by checking the remnant volume of the battery. Battery faulty. No Make the vehicle be in the initialized condition. Inspection start by using self diagnostic mode: Enter into the self diagnostic mode. If operating door control receiver in the order of 1 through 2, the mode turns to diagnostic mode. (1) Insert the key plate in the ignition key cylinder and pull out, then insert it again and turn ignition switch OFF → ON → OFF once within 5 seconds after pulling out. (2) After completing the procedure within 30 seconds, turn the ignition switch OFF → ON → OFF 9 times. HINT: In the case that either of (1) and (2) conditions is not satisfied, transfer to normal mode. When completing self diagnostic mode, turn the ignition switch ON. LOCK and UNLOCK operation is not performed under the self diagnostic mode. within. 5 secs. within. 30 secs. Key plate inserted Key plate not inserted Ignition switch ON 1 OFF 9 9th times 1st time 2001 PRIUS (RM778U) 2 10 BE–80 BODY ELECTRICAL – WIRELESS DOOR LOCK CONTROL SYSTEM No Diagnostic mode operation confirmation: Check the taillight lights up soon after the input operation of self diagnostic mode. Taillight ON Ignition Switch OFF No Is the method to input the diagnostic mode correct? Not enter in diagnostic mode Yes OFF 0.2 sec. Is the function of operation confirmation taillight normal? 0.5 sec.
Taillight light up should be maximum despite the controller. Yes ON No response Transmitter faulty or wireless door lock receiver faulty.
Use another (normal) transmitter and check with the diagnostic mode and in the case that the check result shows the transmitter faulty, it can be judged that wireless door lock receiver is normal. OFF 0.5 sec. (2) Received normal wave of UNLOCK switch. ON OFF 0.2 sec. 0.5 sec. 0.2 sec. (3) Received normal wave of PANIC switch. ON OFF 0.5 sec. 0.5 sec. (4) Compatibility of the recognition code or out from synchronization of rolling code.*. ON OFF While receiving In case of taillight outputs from (1) – (3) 2001 PRIUS (RM778U) Yes Taillight faulty. Confirmation of diagnostic mode: Check taillight light up when pressing on each switch of transmitter. (1) Received normal wave of LOCK switch. 0.2 sec. No In case of taillight outputs of (4) BE–81 BODY ELECTRICAL – WIRELESS DOOR LOCK CONTROL SYSTEM Yes Other body control system faulty. (Transmitter and receiver are normal.) The wave reaching range check: Is the wave reaching range normal? (1 M area around vehicle) (While the transmitting switch is pressed, (approx. 20 secs.) the taillight continuously. After 20 secs., repress the switch again.) When pressing each switch of the new or normal transmitter used in the same type vehicle, check that all taillights chirps in the same way. No Transmitter faulty or wireless door lock receiver faulty. Check the wave reaching range with another transmitter (normal). When the range is normal, transmitter defection is detected, the range is not normal, wireless door lock receiver defection is defected. Yes No Transmitter faulty. Wireless door control receiver check: Check that continuity exists between the receiver terminal 3 (PRG) and body ECU terminal B9 (PRG). Check that continuity exists between the receiver terminal 2 (RDA) and body ECU terminal B10 (RDA). No Wire harness faulty (short circuit). Yes No Check RDA terminal circuit. Check that the voltage of RDA is about 6 – 7 V (when the transmitter is ON). Yes 2001 PRIUS (RM778U) RDA terminal open circuit. BE–82 BODY ELECTRICAL – WIRELESS DOOR LOCK CONTROL SYSTEM No +B power source check: DOME fuse or wire harness faulty. Check that there is constantly 10 to 14 V voltage at the connector terminal 5 (+B) of wireless door control receiver. Yes No Body ground check: Check that continuity exists between the connector terminal 1 (GND) of the wireless door control receiver and body ground. Yes Wireless door control receiver faulty. 2001 PRIUS (RM778U) Wire harness faulty. Body ground open and contact error. BE–83 BODY ELECTRICAL – WIRELESS DOOR LOCK CONTROL SYSTEM BE0OJ–12 INSPECTION 1. INSPECT WIRELESS DOOR LOCK TRANSMITTER OPERATION HINT: Refer to ”Wireless door lock control receiver and transmitter replacement” on page BE–87. (a) Using a screwdriver, remove and cover. (b) Remove the battery (lithium battery). Dry cell battery (1.5 V x 2) I12019 2001 PRIUS (RM778U) (c) Install a new or normal battery (lithium battery). HINT: When a new or normal battery can not be obtained, connect 2 new 1.5 V batteries in series, connect the battery (+) to the battery receptacle side terminal and battery (–) to the bottom terminal, then apply 3 V voltage to the transmitter. (d) In the location where is approx. 1 M away from driver’s outside handle in the right direction, and check the transmitter operation when pressing transmission switch on the surface of the transmitter body. Standard: Remote control of vehicle door lock can be operated. HINT:
The minimum operation distance differs according to operator, the way of holding, and location.
As weak wave is used, operation distance might be shortened when noise is detected in strong wave or used frequency. (e) Install the battery (lithium battery). (f) Install a cover so that rubber cover is not distorted or slipped off. BE–84 BODY ELECTRICAL – WIRELESS DOOR LOCK CONTROL SYSTEM 2. CHECK BATTERY CAPACITY HINT:
Make sure to use the TOYOTA electrical tester.
With the battery unloaded, judge can not be made whether the battery is available or not on the test.
When the transmitter is faulty, the energy amount left in the battery might not be checked correctly.
On the lithium battery used for the transmitter, the voltage more than 2.5 V with the battery unloaded is shown on the tester until the energy is completely consumed. Accordingly when inspecting the energy amount left in the battery, it is necessary to measure the voltage when the battery is loaded. (1.2 kΩ). (a) (b) (c) Remove the cover using a (–) driver. Remove the battery (lithium battery) from the transmitter. Connect the lead to the (–) terminal of the transmitter and install the battery. (d) Connect the (+) tester to the (+) battery (lithium battery), and (–) tester to the lead respectively. Press one of the transmitting switches on the transmitter for approx. 1 second. Press the transmitting switch on the transmitter again to check the voltage. Standard: 2.1 V or more I12020 (e) (f) I12021 2001 PRIUS (RM778U) BE–85 BODY ELECTRICAL – WIRELESS DOOR LOCK CONTROL SYSTEM HINT:


(g) (h) (i) 3. Wire harness side: (a) When the temperature of the battery is low, the judge can not be made correctly. When the outcome of the test is less than 2.1 V, conduct the test again after leaving the battery in the place at 18 °C for more than 30 minutes. By auto power off function, the voltage becomes no load voltage (more than 2.5 V) condition after 20 seconds from the switch was pressed. Make sure to read the voltage before of it. High voltage might be shown 1 to 2 times after leaving the battery, judge should be made with the voltage shown at the 3rd time or later. Disconnect the lead. Set the battery (lithium battery) in the transmitter. Install the cover, so that the rubber cover is not distorted or slipped off. INSPECT WIRELESS DOOR LOCK CONTROL RECEIVER CIRCUIT Disconnect the connector from the receiver and inspect the connector on the wire harness side, as shown below. I12038 Tester connection Condition Specified condition 1 – Ground Constant Continuity 5 – Ground Constant Battery voltage If the circuit is not as specified, inspect the circuit connected to other parts. 2001 PRIUS (RM778U) BE–86 BODY ELECTRICAL (b) From back side: – WIRELESS DOOR LOCK CONTROL SYSTEM Connect the wire harness side connector to the receiver and inspect the wire harness side connector from the back side, as shown below. I12073 Tester connection Condition Specified condition 3 – Ground Normal mode 10 – 14 V 2 – Ground Ignition switch position OFF Key removed Transmitter ON About 6 – 7 V If circuit is as specified, replace the receiver. If the circuit is not as specified, inspect the circuit connected to other parts. 2001 PRIUS (RM778U) BE–87 BODY ELECTRICAL – WIRELESS DOOR LOCK CONTROL SYSTEM BE1D9–02 REPLACEMENT 1. REPLACE TRANSMITTER (LITHIUM) BATTERY NOTICE: Special caution should be taken for handling each component as they are precision electronic components. N30017 (a) Using a screwdriver, remove the cover. NOTICE: Do not pry out the cover forcibly. HINT: Push the cover with a finger as shown in the illustration, so that there becomes clearance, then pry out the cover from that clearance. (b) Remove the transmitter. (c) Remove the battery (lithium battery). NOTICE:  Do not push the terminals with a finger.  If prying up the battery (lithium battery) forcibly to remove, the terminals are deformed. (d) Install a battery (lithium battery) as shown in the illustration. NOTICE: Face the battery upward. Take care not to deform the terminals. (e) Check that the rubber is not distorted or slipped off, and install the cover. N13468 2001 PRIUS (RM778U) BE–88 BODY ELECTRICAL 2. – WIRELESS DOOR LOCK CONTROL SYSTEM REPLACE DOOR CONTROL RECEIVER AND TRANSMITTER NOTICE: When replacing the door control receiver and transmitter, registration of recognition code is necessary because they are provided as single components. (a) Select which operation mode should be performed from the following modes.  Add mode  Rewrite mode  Prohibition mode  Confirmation mode HINT:  The add mode is used to retain codes already registered while you register new recognition codes. This mode is used when adding a transmitter. However, if the number of registered codes exceeds 4 codes, previously registered codes are correspondingly erased in order, starting from the first registered code.  The rewrite mode is used to erase all previously registered codes and register only new recognition codes.  The prohibition mode is used to erase all registered codes and cancels the wireless door lock function. Use this mode when the transmitter is lost.  The confirmation mode is for confirming how many recognition codes are already registered before you register additional recognition codes. (b) Follow the chart on the following pages to register the transmitter recognition code at the wireless door lock control receiver. HINT:  When procedure is out of the specified, the operation returns to normal operation.  Maximum 4 recognition codes can be registered. 2001 PRIUS (RM778U) BE–89 BODY ELECTRICAL – WIRELESS DOOR LOCK CONTROL SYSTEM Start registration of recognition code The vehicle should be in the following conditions.
The key is not inserted in the ignition key cylinder.
Driver’s door is OPEN. (Other doors are CLOSED)
Driver’s door is UNLOCKED. Insert the key into the ignition key cylinder, then pull it out. (Rerform this twice within 5 seconds) Close and open the door (manual operation) 2 times. 1st time Within 40 secs. 2nd time CLOSE OPEN Insert the key into the ignition key cylinder, then pull it out. Again close and open the door (manual operation) 2 times. 1st time 2nd time CLOSE Within 40 secs. OPEN Close the all door and insert the key into the ignition key cylinder. 2001 PRIUS (RM778U) BE–90 BODY ELECTRICAL – WIRELESS DOOR LOCK CONTROL SYSTEM Turn the ignition switch from ON to LOCK at approx. 1 sec. interval 1 to 5 times to select the mode. Confirmation mode Add mode ON – LOCK change occurs 1 time ON – LOCK change occurs 3 times Approx. Approx. 1 sec. 1 sec. Approx. 1 sec. ON ON LOCK LOCK Prohibition mode Rewrite mode ON – LOCK change occurs 2 times ON – LOCK change occurs 5 times Approx. Approx. 1 sec. 1 sec. Approx. Approx. 1 sec. 1 sec. ON ON LOCK LOCK Pull out the key from the ignition key cylinder. When add mode or rewrite mode is selected. Door control relay automatically performs the LOCK–UNLOCK operation once or twice at 1 sec. interval to inform the operator that either the add mode or rewrite mode has been selected. LOCK–UNLOCK occurs once Within Indicates that add mode has been selected. 3 secs. 1 sec. LOCK UNLOCK When prohibition mode is selected. Door control relay automatically performs the LOCK–UNLOCK operation 1 to 4 times at 2 sec. interval to inform the operator of the number of the registered codes. HINT: When the number of the registered code is 0, the operation is automatically performed 5 times. Example: When the operation is performed twice, it directs that 2 types of recognition code have been registered. LOCK–UNLOCK occurs twice Indicates that rewrite mode has been selected. 1 sec. 1 sec. LOCK When confirmation mode is selected. 1st time 2nd time 2 secs. 2 secs. LOCK UNLOCK UNLOCK Registration of recognition code (Confirmation mode and prohibition mode) is completed. 2001 PRIUS (RM778U) BE–91 BODY ELECTRICAL – WIRELESS DOOR LOCK CONTROL SYSTEM When prohibition mode is selected. Within 40 secs. Door control relay performs LOCK–UNLOCK operation 5 times at a 1 sec. interval to inform the operator that prohibition mode has been selected. Approx. Approx. 1 sec. 1 sec. LOCK UNLOCK Press the lock and unlock switches on the transmitter switch simultaneously for more than between 1 sec. or more and 1.5 sec. below. Within 3 secs. Press one of 3 switches on the transmitter. Door control relay automatically performs LOCK–UNLOCK operation once or twice at a 1 sec. interval to inform the operator that the receiver has received the signal from the transmitter. LOCK–UNLOCK occurs once Within 3 secs. Registration of recognition code is completed LOCK–UNLOCK occurs twice Registration of recognition code has not been completed.
Recognition code received first time and second time did not match.
When selecting add mode, a registered recognition code was received. If LOCK–UNLOCK operation can not be performed at all, the mode returns to the normal mode, then start with ”Start registration of recognition code”. Proceed to finish registration Proceed to continue registration Within 40 secs. If even one of the following conditions is satisfied, registration of recognition codes is completed.
40 secs. elapses since the door control relay response.
The driver’s door is opened.
The key plate is inserted in the ignition key cylinder.
4 type recognition codes are registration at one time. Registration of recognition codes (add mode or rewrite mode) is completed. 2001 PRIUS (RM778U) BE–93 BODY ELECTRICAL – POWER MIRROR CONTROL SYSTEM BE1UW–01 INSPECTION 1. LEFT SIDE RIGHT SIDE UP OFF LEFT RIGHT 2. DOWN I11900 INSPECT LEFT SIDE MIRROR SWITCH CONTINUITY Switch position Tester connection Specified condition OFF – UP 4–8 6–7 Continuity DOWN 4–7 6–8 Continuity LEFT 5–8 6–7 Continuity RIGHT 5–7 6–8 Continuity No continuity INSPECT RIGHT SIDE MIRROR SWITCH CONTINUITY Switch position Tester connection Specified condition OFF – UP 3–8 6–7 Continuity DOWN 3–7 6–8 Continuity LEFT 5–8 6–7 Continuity RIGHT 2–7 6–8 Continuity No continuity If continuity is not as specified, replace the switch. If continuity is as specified, inspect the switch circuit. 3. INSPECT MIRROR SWITCH CIRCUIT Disconnect the connector from the switch and inspect the connector on the wire harness side. Wire Harness Side 1 2 3 4 5 6 7 8 910 N21376 Tester connection Condition Specified condition 7 – Ground Constant Continuity 8 – Ground Ignition switch position LOCK No voltage 8 – Ground Ignition switch position ACC or ON Battery voltage If the circuit is not as specified, inspect the circuits connected to other parts. 2001 PRIUS (RM778U) BE–94 BODY ELECTRICAL 1 – POWER MIRROR CONTROL SYSTEM 4. (a) INSPECT MIRROR MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 3 and the negative (–) lead to terminal 1, and check that the mirror turns right side. (b) Reverse the polarity, and check that the mirror turns left side. (c) Connect the positive (+) lead from the battery to terminal 3 and the negative (–) lead to terminal 5, and check that the mirror turns to the downward. 3 I01811 1 3 I01812 3 5 I01813 (d) Reverse the polarity, and check that the mirror turns to the upward. If operation is not as specified, replace the mirror assembly. 3 5 I01814 2001 PRIUS (RM778U) BE–95 BODY ELECTRICAL – AUDIO SYSTEM AUDIO SYSTEM BE1UU–01 DESCRIPTION 1. RADIO WAVE BAND The radio wave bands used in radio broadcasting are as follows: 30 kHz Frequency Designation 3 MHz 300 kHz LF Modulation method 300 MHz VHF HF MF AM Radio wave 30 MHz FM Amplitude modulation Frequency modulation LF: Low frequency MF: Medium Frequency HF: High Frequency VHF: Very High Frequency 2. SERVICE AREA There are great differences in the size of the service area for AM and FM monaural. Sometimes FM stereo broadcasts cannot be received even through AM comes in very clearly. Not only does FM stereo have the smallest service area, but it also picks up static and other types of interference (”noise”) easily. FM (Stereo) FM (Monaural) AM BE2818 3. RECEPTION PROBLEMS Besides the problem of static, there are also the problems called ”fading”, ”multipath” and ”fade out”. These problems are caused not by electrical noise but by the nature of the radio waves themselves. Fading
Ionosphere Fading Besides electrical interference, AM broadcasts are also susceptible to other types of interference, especially at night. This is because AM radio waves bounce off the ionosphere at night. These radio waves then interfere with the signals from the same transmitter that reach the vehicle’s antenna directly. This type of interference is called ”fading”. BE2819 2001 PRIUS (RM778U) Author: Date: 1762 BE–96 BODY ELECTRICAL Multipath – AUDIO SYSTEM
Multipath One type of interference caused by bouncing of radio waves off obstructions is called ”multipath”. Multipath occurs when a signal from the broadcast transmitter antenna bounces off buildings and mountains and interferes with the signal that is received directly.
Fade Out Because FM radio waves are of higher frequencies than AM radio waves, they bounce off buildings, mountains, and other obstructions. For this reason, FM signals often seem to gradually disappear or fade away as the vehicle goes behind a building or other obstructions. This is called ”fade out”. BE2820 Fade Out BE2821 4. Example : Head Capstan (a) (b) Pinch Roller Tape Player/Head Cleaning: MAINTENANCE Raise the cassette door with your finger. Next, using a pencil or similar object, push in the guide. Using a cleaning pen or cotton applicator soaked in cleaner, clean the head surface, pinch rollers and capstans. N17398 5. CD Player/Disc Cleaning: MAINTENANCE If the disc gets dirty, clean the disc by wiping the surface from the center to outside in the radial directions with a soft cloth. NOTICE: Do not use a conventional record cleaner or anti–static preservative. BE4331 2001 PRIUS (RM778U) Author: Date: 1763 BE–97 BODY ELECTRICAL – AUDIO SYSTEM BE1UV–01 TROUBLESHOOTING 1. DIAGNOSIS SYSTEM MODE (w/o Navigation system) HINT: Diagnosis System Mode is operated as follows. In case of a vehicle without navigation system, there is no navigation check mode. However, other modes except for this are same as a vehicle with navigation system. Audio system normal operation Diagnosis start–up. (refer to next page) to 2. SYSTEM CHECK MODE SCREEN HINT: When Diagnosis System mode is started, system check is performed at first and the check result is displayed. to 4. DISPLAY CHECK MODE SCREEN 2001 PRIUS (RM778U) I17103 BE–98 BODY ELECTRICAL – AUDIO SYSTEM (a) DIAGNOSIS START–UP To start the diagnosis menu, there are 2 ways: using a diagnosis check wire and using a switch. (b) START–UP BY SWITCH OPERATION (1) Vehicle speed is 0 km/h (0 mph). (2) Parking brake switch is pressed. (3) Press the Display switch to display the Screen Adjustment screen. I15593 (4) Concealed touch switch Repeatedly touch the upper and lower bottom parts of the left end of the screen 3 times. I17110 (c) 2. FINISHING DIAGNOSIS SYSTEM MODE Turn the ignition switch from ACC to OFF to finish the mode. If it is started by switch operation. DIAGNOSIS SYSTEM MODE (w/ Navigation system) (See page DI–789) 2001 PRIUS (RM778U) BE–102 BODY ELECTRICAL – CLOCK CLOCK BE1UT–01 TROUBLESHOOTING HINT: Troubleshoot the clock according to the table below. Troubleshooting No. Clock will not operate 1 Clock loses or gains time 2 ± 1.5 seconds / day E ILL Ground 3 Clock Side: Power Source (Illumination) Wire Harness Side: Power Source (System Operation) B ACC Connector: 2 4 Power Source (Display Operation) I01856 1. TROUBLESHOOTING No.1 1 CLOCK WILL NOT OPERATE Clock Side: Wire Harness Side: (a) Check that the battery positive voltage is 10 – 16 V. If voltage is not as specified, replace the battery. (b) Check that the DOME fuse is not blown. If the fuse is blown, replace the fuse and check for short. (c) Troubleshoot the clock as follows. HINT: Inspect the connector on the wire harness side. B + GND e–4–2–D e–4–1–D I01857 Is there battery positive voltage between terminal +B and body ground. No Open or short circuit in wire harness between terminal +B and DOME fuse. No Open or short circuit in wire harness between terminal GND and DOME fuse. Yes Is there continuity between terminal GND and body ground. Yes Replace clock. 2001 PRIUS (RM778U) Author: Date: 1769 BE–103 BODY ELECTRICAL 2. – CLOCK TROUBLESHOOTING NO.2 2 CLOCK LOSES OR GAINS TIME (a) Check that the battery positive voltage is 10 – 16 V. If voltage is not as specified, replace the battery. (b) Inspect the error of the clock. Allowable error (per day): ± 1.5 seconds If the error exceeds the allowable error, replace the clock. (c) Check that the clock adjusting button is sticking in position and has failed to return. If the error exceeds the allowable error, replace the clock. (d) Troubleshoot the clock as follows. HINT: Inspect the connector on the wire harness side. Clock Side Wire Harness Side B+ GND I01858 Is there battery voltage between terminal +B and body ground? Bellow 10 V Locate cause and repair, or recharge battery. Bellow 10 V Locate cause and repair, or recharge battery. Yes Is there battery voltage between terminal ACC and body ground? Yes Adjust or replace clock. 2001 PRIUS (RM778U) Author: Date: 1770 BE–104 BODY ELECTRICAL – HYBRID VEHICLE IMMOBILISER SYSTEM BE1W9–01 HYBRID VEHICLE IMMOBILISER SYSTEM REGISTRATION PROCEDURE 1. (a) (b) (c) (d) 2. THE COMMUNICATION BETWEEN THE HYBRID VEHICLE CONTROL ECU AND THE TRANSPONDER KEY ECU IS AS FOLLOWS When the ignition is turned ON, the transponder key ECU checks if the key is pre–registered or not and sends the check result to the hybrid vehicle control ECU. When the hybrid vehicle control ECU confirms that the key is pre–registered, it transmits its own ID (random numbers) to the transponder key ECU. Receiving the ID, the transponder key ECU calculates internally and sends the calculated result back to the hybrid vehicle control ECU. The hybrid vehicle control ECU rechecks the calculation inside the ECU. When the calculation result corresponds to its own ID, this enables the engine to start. PREASE DO THE FOLLOWING PROCEDURES WHEN YOU EXCHANGE TRANSPONDER KEY ECU HINT: When replacing the transponder key ECU or hybrid vehicle control ECU, start the engine after leaving it for more than 30 minutes with the ignition switch ON position. (a) (Case 1): Replace the transponder key ECU. →Register the new transponder key codes. →Leave more than 30 minutes with the ignition switch ON. →Start the engine. (b) (Case 2): Replace the hybrid vehicle control ECU. →Leave more than 30 minutes with the ignition switch ON. →Start the engine. (c) (Case 3): Replace the transponder key ECU and hybrid vehicle control ECU. →Register the new transponder key codes. →Start the engine. 3. IF ALL KEYS ARE LOST, OBSERVE THE FOLLOWING (a) Purchase a new transponder key ECU and a new key. (b) Replace the transponder key ECU with new one. (c) Insert a new key into the key cylinder, turn the ignition switch ON and leave it as it is for 30 min. 4. SETTING HYBRID VEHICLE IMMOBILISER SYSTEM (a) Removing a key from the key cylinder sets hybrid vehicle immobiliser system. (b) When 20 sec is elapsed after the key is turned from ignition switch ON to ACC or LOCK, the hybrid vehicle immobiliser is set. 5. UNSETTING HYBRID VEHICLE IMMOBILISER SYSTEM Insert a key into the key cylinder (Under this condition, transponder key ECU starts communication with the transponder chip built in the key. When the ID code in the chip coincides with that registered in ECU consecutively 2 times, the hybrid vehicle immobiliser system is reset). 2001 PRIUS (RM778U) Author: Date: 1771 BE–105 BODY ELECTRICAL – HYBRID VEHICLE IMMOBILISER SYSTEM 6. KEY REGISTRATION IN AUTOMATIC REGISTRATION MODE (a) Registration of a new transponder key. HINT:
This must be done when you install a new transponder key ECU.
It is possible to register up to 2 master key codes and a sub key code.
In the automatic registration mode, the last key registered becomes sub–key. (b) Initial condition: Battery connected, no key in key cylinder. Start Security indicator is flashing Insert a master key (black) into the key cylinder. Security indicator goes off for 1 sec. and then lights up. Master key 1 Remove the master key. Insert the other master key (black) into the key cylinder. Security indicator goes off for 1 sec. and then lights up. Master key 2 Remove the master key. Insert the sub key (gray) into the key cylinder. Security indicator goes off for 1 sec. and then lights up again. Sub key Remove the sub key Security indicator is flashing. End 2001 PRIUS (RM778U) Author: Date: 1772 BE–106 BODY ELECTRICAL – HYBRID VEHICLE IMMOBILISER SYSTEM HINT:
When a key is not inserted in the key cylinder on the automatic registration mode, the security indicator always lights on. When the immobiliser system operates normally and the key is pull out, the security indicator blinks. When key code registration could not be performed on the automatic registration mode, code 2–1 is output from the security indicator and when inserting the already registered key, code 2–2 is output.

Blinks Code 2–1 0.25 Sec. 1.8 Sec. 0.2 Sec. (c) 1 Sec. 0.25 Sec. 0.5 Sec. Code2–2 0.25 Sec. 1 Sec. 0.25 Sec.0.5 Sec. Automatic registration mode completion If completing the mode forcibly when more than 1 key code have been registered on the automatic registration mode, perform the following procedures. After 1 more key code have been registered with master key, turn the ignition switch from LOCK to ON 5 times within 10 secs. after inserting the already registered key or without pulling the key out. 2001 PRIUS (RM778U) Author: Date: 1773 BE–107 BODY ELECTRICAL – HYBRID VEHICLE IMMOBILISER SYSTEM 7. REGISTERING MASTER KEY Initial condition: All doors closed, not key in cylinder. Start Insert a master key into the key cylinder. Within 15 secs. Repeatedly turn the key from ignition switch LOCK to ON 5 times. Repeat driver’s door open/close operation 6 times. *1 Within 20 secs. Remove the master key. *2 Within 10 secs. Insert the key to be registered into the key cylinder. *3 Within 10 secs. Turn the key from ignition switch LOCK to ON and stay for 60 secs. or more. *4 Within 10 secs. Remove the key from the key cylinder. Yes *5 Register next key? No Open and close a driver’s door. End *1: *2: *3: *4: *5: The 1 st door’s open/close operation should be within 15 sec after key insertion. Remove the key within 20 sec. after the 1 st door’s open/close operation. Insert the key within 10 sec. after preceding key removal. Turn the key from ignition switch LOCK to ON within 10 sec. after key insertion. If registering the other key, insert it into the key cylinder within 10 sec. 2001 PRIUS (RM778U) Author: Date: 1774 BE–108 BODY ELECTRICAL – HYBRID VEHICLE IMMOBILISER SYSTEM 8. REGISTERING SUB–KEY Initial condition: All doors closed, not key in cylinder. Start Insert a master key into the key cylinder. Within 15 secs. Repeatedly turn the key from ignition switch LOCK to ON 4 times. Repeat door’s open/close operation 5 times. *1 Within 20 secs. Remove the master key. *2 Within 10 secs. Insert the key to be registered into the key cylinder. *3 Within 10 secs. Turn the key from ignition switch LOCK to ON and stay for 60 secs. or more. *4 Within 10 secs. Remove the key from the key cylinder. Yes *5 Register next key? No Open and close a door once. End *1: *2: *3: *4: *5: The 1 st door’s open/close operation should be within 15 sec after key insertion. Remove the key within 20 sec. after the 1 st door’s open/close operation. Insert the key within 10 sec. after preceding key removal. Turn the key from ignition switch LOCK to ON within 10 sec. after key insertion. If registering the other key, insert it into the key cylinder within 10 sec. 2001 PRIUS (RM778U) Author: Date: 1775 BE–109 BODY ELECTRICAL – HYBRID VEHICLE IMMOBILISER SYSTEM 9. ERASURE OF TRANSPONDER KEY CODE (a) Do this operation to erase transponder key registration from the transponder key ECU. HINT: Delete all other master and sub–key codes leaving the master key code to use the operation. When using the key which was used before deletion, it is necessary to register the code again. (b) Initial condition: All doors closed, not key in cylinder. Start Insert a master key into the key cylinder. Repeatedly turn the key from ignition switch LOCK to ON 6 times. Within 15 secs. Repeat driver’s door open/close operation 7 times. *1 Within 20 secs. Remove the master key. *2 End *1: The 1 st door’s open/close operation should be done within 15 sec after key insertion. *2: Remove the key within 20 sec. after the 1 st door’s open/close operation. 2001 PRIUS (RM778U) Author: Date: 1776 BE–111 BODY ELECTRICAL – HYBRID VEHICLE IMMOBILISER SYSTEM BE1WC–01 PRE–CHECK Check Connector 1. (a) TRANSPONDER KEY ECU INPUT CONDITION DISPLAY READ CODE Connect the positive (+) lead from the volt meter (Analog Type) to OP1 of the check connector and the negative (–) lead to E1 of the check connector. OP1 I17846 0.5 sec. ON 1.5 sec. Example 2.5 sec. 4.5 sec. OFF Code 11 Code 21 I01826 Code 2001 PRIUS (RM778U) (b) Insert the ignition key in the key cylinder. (c) Read the code from the movement of the tester needle. If no code is output, turn the ignition switch ON. If a code is now output, check if the DOME fuse is blown. HINT:
The code can be read using a luminous diode (Recommend activation current 10 – 20 mA) instead of a tester.
A digital tester can also be used. Display condition:
When there are multiple codes, they are output in order staring from the lowest code.
After all the codes are output, Lo is displayed for 4.5 secs., then all the code are output again starting from the lowest code.
If the situation changes during code output, Lo is output for 4.5 secs. after output of the current code ceases, then the codes are output again starting from the lowest code. E.g. while 11 (out of 11 and 21) is being output, conditions change and 12 is added. So after 11 is output, Lo is output for 4.5 secs., then 11, 12 and 21 are output. 2. TRANSPONDER KEY ECU INPUT CONDITION DISPLAY CODE LIST Output condition 11 Key unlock warning switch ON (Ignition key inserted) 12 Any door is open. (Door courtesy switch ON) 13 Ignition switch at ON position 21 Master key is inserted in key cylinder and the immobiliser system is OFF. 22 Sub key is inserted in key cylinder and immobiliser system is OFF. 31 Key code recorded in transponder key ECU differs from code of key inserted in key cylinder. 32 Transponder key code cannot be read. 33 Key code cannot be read because format of chip inside key is wrong. 34 Transponder key ECU has no memory space to register key code. 52 Hibrid vehicle control ECU is unlocked. BE–112 BODY ELECTRICAL – HYBRID VEHICLE IMMOBILISER SYSTEM 53 Hibrid vehicle control ECU code is error. 54 Hibrid vehicle control ECU is check–sum error. 55 Hibrid vehicle control ECU is factory code initialling. 58 No response from hibrid vehicle control ECU 3. TRANSPONDER KEY ECU INPUT CONDITION DISPLAY MALFUNCTION LIST Symptom Cause No code is output. 1. DOME Fuse 2. Wire harness or connector 3. Transponder key ECU Even when key is inserted in key cylinder, Code 11 is not output. 1. Key unlock warning switch 2. Wire harness or connector 3. Transponder key ECU Code 12 is not output when the door is open. 1. Door courtesy switch 2. Wire harness or connector 3. Transponder key ECU Code 13 is not output when ignition switch ON. 1. IGN Fuse 2. Wire harness or connector 3. Transponder key ECU Code 31 is not output when key is inserted in key cylinder. Key code is not registered. Code 32 is output. 1. Transponder key coil 2. Transponder key ECU 3. Wire harness or connector Code 33 is output. Transponder key ECU Code 34 is output. Transponder key ECU has no memory space to register key code. Code 51–58 is output. 1. Hibrid vehicle control ECU 2. Transponder key ECU 2001 PRIUS (RM778U) BE–113 BODY ELECTRICAL 4. – HYBRID VEHICLE IMMOBILISER SYSTEM TROUBLE SHOOTING The engine dose not starting? Yes Is DTC code 21, 22 output?
Check the wire harness and connector between the hybrid vehicle control ECU and transponder key ECU.
Check that wire harness and connector between the engine ECU and transponder key ECU. No Is DTC code 31, 32, 33 output? DTC 31 Go to (a) DTC 32 Go to (b) DTC33 Go to (C) No
Wire harness faulty (Open circuit)
Transponder key EUC faulty
If code 31 is output, troubleshoot according to this flow chart. Register the transponder key again. OK Hybrid vehicle immobiliser system is normal. 2001 PRIUS (RM778U) NG If it cannot be registered (due to chip failure), replace the key. BE–114 BODY ELECTRICAL
– HYBRID VEHICLE IMMOBILISER SYSTEM If code 32 is output, troubleshoot according to this flow chart. Can the engine be started with any other key of the vehicle? YES Replace the key (Chip failure) NO Does continuity exist in the coil in continuity test? NO Replace the coil (Coil broken) YES Replace the AMP and check if it starts? YES Replace the AMP (AMP failure) NO Does continuity exist in W/H in continuity test? NO YES
Repair or replace the wire harness or the connector. Replace the Transponder key ECU (Transponder key ECU failure) If code 33 is output, troubleshoot according to this flow chart. Can the engine be started with any other key of the vehicle? YES Replace the key (Chip failure) NO Replace the AMP and check if it starts? NO 2001 PRIUS (RM778U) YES Replace the AMP (AMP failure) Replace the Transponder key ECU (Transponder key ECU failure) BE–117 BODY ELECTRICAL – HORN SYSTEM BE0FZ–14 INSPECTION 1. (a) (b) (c) (d) I17863 INSPECT HORN SWITCH Disconnect the negative (–) terminal from the battery. Remove the left and right covers from the steering wheel. Using a torx socket wrench, loosen the 2 bolts. Pull up the horn pad and place it on the steering column, as shown. HINT: Do not disconnect the connector from the horn pad. (e) Disconnect the connector from the slip ring. (f) I11734 Check that no continuity exists between terminal 6 of the connector and body ground. (g) Check that continuity exists between terminal 6 of the connector and body ground when the horn contact plate is pressed against the steering spoke assembly. If continuity is not as specified, repair or replace the steering wheel or wire harness as necessary. (h) Install the horn pad in place and using a torx socket wrench, torque the 2 bolts. Torque: 7.1 N·m (72 kgf·cm, 62 in.·lbf) (i) Install the left and right covers. (j) Connect the negative (–) terminal to the battery. 2. INSPECT HORN OPERATION Connect the positive (+) lead from the battery to the terminal and negative (–) lead to the horn body and check that the horn blows. If operation is not as specified, replace the horn. BE3907 2001 PRIUS (RM778U) BE–118 BODY ELECTRICAL 3. 1 2 3 5 5 1 2 3 I01200 2001 PRIUS (RM778U) – HORN SYSTEM INSPECT HORN RELAY CONTINUITY Condition Tester connection Constant 1–2 Continuity Specified condition Apply B+ between terminals 1 and 2. 3–5 Continuity If continuity is not as specified, replace the relay. BO–1 BODY – CLIP CLIP BO0ZO–06 REPLACEMENT The removal and installation methods of typical clips used in body parts are shown in the table below. HINT: If the clip is damaged during the operation, always replace it with a new clip. Shape (Example) Removal/Installation Pliers Clip Remover Screwdriver Scraper V00005 2001 PRIUS (RM778U) Author: Date: 1786 BO–2 BODY Shape (Example) – CLIP Removal/Installation Removal Removal Installation Installation V00012 2001 PRIUS (RM778U) Author: Date: 1787 BO–3 BODY – SRS AIRBAG SRS AIRBAG BO0XI–05 PRECAUTION The PRIUS is equipped with an SRS (Supplemental Restraint System) such as the driver airbag, front passenger airbag and side airbag. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices in the RS section. 2001 PRIUS (RM778U) Author: Date: 1788 BO–11 BODY – FRONT DOOR BO3QK–01 DISASSEMBLY H13682 1. REMOVE INSIDE HANDLE BEZEL (a) Using a screwdriver, open the screw cap. HINT: Tape the screwdriver tip before use. (b) Remove the screw. (c) Using a screwdriver, remove the inside handle bezel as shown in the illustration. HINT: Tape the screwdriver tip before use. 2. REMOVE POWER WINDOW SWITCH (a) Remove the screw. (b) Using a screwdriver, remove the power window switch. HINT: Tape the screwdriver tip before use. (c) Disconnect the connectors. Clip H15388 3. (a) REMOVE LOWER FRAME BRACKET GARNISH Using a screwdriver, remove the lower frame bracket garnish. HINT: Tape the screwdriver tip before use. (b) Remove the front flame cover. : 2 Clips H15389 4. (a) (b) 7 Clips 2001 PRIUS (RM778U) H15390 REMOVE DOOR TRIM Remove the clip. Insert a screwdriver between the door panel and door trim to pry the trim out. NOTICE: Be careful not damage the door panel and trim. HINT: Tape the screwdriver tip before use. (c) Pull the door trim upward to remove it. BO–12 BODY – FRONT DOOR 5. REMOVE INSIDE HANDLE Remove the screw and inside handle, disconnect the 2 cables from the inside handle as shown in the illustration. H15391 H15392 6. REMOVE SERVICE HOLE COVER (a) Remove the 2 screws and door trim No. 1 bracket. (b) Remove the 2 grommets. (c) Remove the service hole cover. NOTICE: Do not tear the cover. HINT:
At the time of reassembly, please refer to the following item.
Bring out the 2 control cables and wire harness through the service hole cover. 7. (a) (b) Drill H15393 2001 PRIUS (RM778U) REMOVE SPEAKER Disconnect the connecter. Using a drill of less then ø 4 mm (0.16 in), drill out the rivet heads and remove the speaker. (c) Gently and vertically put the drill to the rivet, and cut the rivet flanges. NOTICE:
Prizing the hole with a drill can lead to damage to the rivet hole or breaking the drill.
Take cafe as the cut rivet is hot. (d) Even if flange is taken off, continue drilling and push out remaining fragments will the drill. (e) Using a vacuum cleaner, remove the drilled rivet and their dust from the inside of the door. BO–13 BODY – FRONT DOOR HINT: At the time of reassembly, please refer to the following item. Using an air riveter and nose piece No.1, strike rivets into the door panel to install the speaker to the door panel. Air Riveter H15394 Mandrel H00475 Protective Tape NOTICE: At the time of reassembly, please refer to the following item. If the rivet is not positioned perpendicularly it will bend the mandrel. When the trigger is then pulled, it may damage the air riveter. 8. REMOVE OUTSIDE VIEW MIRROR (a) Disconnect the connecter. (b) Remove the 3 nuts andout side view mirror. Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf) 9. REMOVE DOOR BELT MOULDING Using a scraper, remove the door belt moulding. HINT: Tape the scraper tip before use. 10. REMOVE DOOR LOCK SILENCER H15395 11. (a) REMOVE DOOR GLASS Remove the 3 bolts and reinforce inside extension. H15408 (b) H15407 2001 PRIUS (RM778U) Open the door glass until the door belts appear in the service hole. (c) Remove the 2 bolts. NOTICE: Be careful not to drop the door glass. (d) Pull the door glass upward to remove it. 12. REMOVE DOOR GLASS RUN 13. REMOVE LOWER FLAME Remove the 2 nuts, plate and lower flame. BO–14 BODY REMOVE WINDOW REGULATOR Disconnect the connector. (b) Remove the 2 bolts from the window regulator. Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf) Remove the 4 bolts and window regulator. Torque: 8.3 N·m (85 kgf·cm, 74 in.·lbf) HINT: At the time of reassembly, please refer to the following item. Apply MP grease to the window regulator. NOTICE: At the time of reassembly, please refer to the following item. Do not apply grease to the spring of the window regulator. 15. (a) (b) (c) (d) (e) H15436 FRONT DOOR 14. (a) (c) H15435 – REMOVE DOOR LOCK Disconnect the control cable from the clamp. Disconnect the 2 links from the outside handle and key cylinder. Disconnect the connecter. Remove the bolt. Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf) Remove the 3 screws and door lock. Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf) HINT: At the time of reassembly, please refer to the following item.
Apply adhesive to the 3 screws. Part No. 08833–00070, THREE BOND 1324 or equivalent 2001 PRIUS (RM778U) BO–15 BODY
16. (a) (b) H10815 2001 PRIUS (RM778U) – FRONT DOOR Apply MP grease to the sliding and rotating parts of the door lock. REMOVE OUTSIDE HANDLE Remove the 2 bolts and outside handle. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) Remove the key cylinder from the handle. BO–19 BODY – REAR DOOR BO3QO–01 DISASSEMBLY H13682 1. REMOVE INSIDE HANDLE BEZEL (a) Using a screwdriver, open the screw cap. HINT: Tape the screwdriver tip before use. (b) Remove the screw. (c) Using a screwdriver, remove the inside handle bezel as shown in the illustration. HINT: Tape the screwdriver tip before use. 2. REMOVE POWER WINDOW SWITCH (a) Remove the screw. (b) Using a screwdriver, remove the power window switch. HINT: Tape the screwdriver tip before use. (c) Disconnect the connector. Clip H13683 3. REMOVE REAR DOOR LOWER BRACKET GARNISH Using a screwdriver, remove the rear door lower bracket garnish. HINT: Tape the screwdriver tip before use. 2 Clips H13684 4. (a) (b) 7 Clips 2001 PRIUS (RM778U) H13685 REMOVE DOOR TRIM Remove the clip. Insert a screwdriver between the door panel and door trim to pry the trim out. NOTICE: Be careful not to damage the door panel and trim. HINT: Tape the screwdriver tip before use. (c) Pull the trim upward to remove it. BO–20 BODY – REAR DOOR 5. REMOVE INSIDE HANDLE Remove the screw and inside handle, disconnect the 2 cables from the inside handle as shown in the illustration. 6. REMOVE DOOR TRIM BRACKET NO. 1 Remove the 2 screws and door trim bracket, then remove the 2 grommets. H15391 7. REMOVE SERVICE HOLE COVER Remove the service hole cover. NOTICE: Do not tear the cover. HINT: At the time of reassembly, please refer to the following item. Bring out the 2 control cables and wire harness through the service hole cover. H15429 8. REMOVE DOOR BELT MOULDING Using a scraper, remove the door belt moulding. HINT: Tape the scraper tip before use. 9. REMOVE DOOR LOCK LINK SILENCER 10. REMOVE DOOR GLASS RUN 11. REMOVE WEATHERSTRIP Protective Tape H15430 12. (a) (b) REMOVE DIVISION BAR Remove the 2 bolts and screw. Pull the division bar forward. (c) Rotate the division bar 90° and pull it upward as shown in the illustration. REMOVE QUARTER WINDOW GLASS Remove the quarter window glass with the weatherstrip. Remove the weatherstrip from the quarter window glass. H15427 13. (a) (b) H15428 2001 PRIUS (RM778U) BO–21 BODY H13687 – REAR DOOR 14. REMOVE INSIDE PANEL PLATE Remove the 3 screws and inside panel plate. 15. REMOVE INSIDE PANEL REINFORCEMENT Remove the 4 screws and inside panel plate. 16. REMOVE DOOR GLASS (a) Side out the door glass from the window regulator. NOTICE: Be careful not to drop the door glass. (b) Pull the door glass upward to remove it. 17. REMOVE WINDOW REGULATOR Disconnect the connector, then remove the 4 bolts and window regulator. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) HINT: Remove the regulator through the service hole. H15431 HINT: At the time of reassembly, please refer to the following item. Apply MP grease to the window regulator. H15432 18. (a) (b) (c) H15433 2001 PRIUS (RM778U) REMOVE DOOR LOCK Remove the child protection cover. Disconnect the connector. Using a screwdriver, remove the door lock link guide and clamp. HINT: Tape the screwdriver tip before use. (d) Remove the 3 screws. Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf) HINT: At the time of reassembly, please refer to the following item. Apply adhesive to the 3 screws. Part No. 08833–00070, THREE BOND 1324 or equivalent (e) Remove the bolts. (f) Remove the door lock through the service hole. BO–22 BODY – REAR DOOR HINT: At the time of reassembly, please refer to the following item. Apply MP grease to the sliding and rotating parts of the door lock. 19. REMOVE OUTSIDE HANDLE (a) Remove the 2 bolts. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) (b) Remove the outside handle and key cylinder. H15434 2001 PRIUS (RM778U) BO–26 BODY – LUGGAGE COMPARTMENT DOOR AND HINGE BO3QS–01 REMOVAL H15480 1. REMOVE LUGGAGE COMPARTMENT DOOR TRIM Remove the 10 clips and luggage compartment door trim. 2. REMOVE LUGGAGE COMPARTMENT DOOR LOCK (a) Remove the 2 bolts and luggage compartment door lock. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) (b) Disconnect the link and cable from the lock. 3. REMOVE LUGGAGE COMPARTMENT DOOR OUTER GARNISH (a) Remove the 4 nuts. (b) Remove the luggage compartment door outer garnish and key cylinder. 4. (a) (b) (c) (d) REMOVE LICENCE PLATE LIGHT Disconnect the connector. Remove the licence plate light as shown in the illustration. Employ the same manner described above to the other side. Using a clip remover, remove the clamps. H15418 5. REMOVE LUGGAGE COMPARTMENT DOOR Remove the 4 bolts luggage compartment door. Torque: 8.3 N·m (85 kgf·cm, 74 in.·lbf) H15419 6. (a) (b) 7. H15420 2001 PRIUS (RM778U) REMOVE LUGGAGE REAR FLOOR FINISH PLATE Using a clip remover, remove the 4 clips. Remove the rear floor finish plate. REMOVE LUGGAGE COMPARTMENT DOOR WEATHERSTRIP BO–27 BODY 8. (a) (b) (c) (d) 9. 10. 11. 12. 13. 5 Clips H13694 (b) H15384 2001 PRIUS (RM778U) LUGGAGE COMPARTMENT DOOR AND HINGE REMOVE LUGGAGE COMPARTMENT SIDE TRIM COVER LH AND RH Remove the 3 clips and lower side luggage compartment cover. Remove the clip and warning reflector holder. Remove the warning reflector box. Remove the 4 clips and luggage compartment side trim cover LH and RH. REMOVE REAR SEAT CUSHION (See page BO–83) REMOVE REAR SEATBACK (See page BO–83) REMOVE LUGGAGE TRIM NO. 2 COVER REMOVE LUGGAGE COMPARTMENT TRIM COVER REMOVE UPPER PART OF REAR DOOR OPENING TRIMS 14. REMOVE ROOF SIDE INNER GARNISH (a) Using a screwdriver, disengage the clips. HINT: Tape the screwdriver tip before use. (b) Pull the garnish upward to remove it. (c) Employ the same manner described above to the other side. 15. REMOVE CRS TETHER ANCHOR Remove the 3 CRS tether anchor covers and 3 CRS tether anchor brackets. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) 16. (a) 4 Clips – (c) 17. 18. 19. (a) REMOVE PACKAGE TRAY TRIM PANEL Pull the package tray trim panel upward to disengage the clips. Remove the rear seat outer belts through the cut out on the package tray trim. Pull the package tray trim panel forward to remove it. REMOVE SILENCER PAD REMOVE ROOM PARTITION PANEL REMOVE TORSION BAR Remove the torsion bars from center bracket. BO–28 BODY – LUGGAGE COMPARTMENT DOOR AND HINGE (b) Install SST to the torsion bar on the hinge side. SST 09804–24010 (c) Push down on SST, and pull the luggage compartment door hinge from the torsion bar. Slowly lift SST, and remove the torsion bar from the torsion bar bracket with SST. SST H15422 (d) SST H15423 (e) (f) Disconnect the torsion bar from the bracket. Employ the same manner described above to the other side. 20. REMOVE LUGGAGE COMPARTMENT DOOR HINGE Remove the pin and luggage compartment door hinge. H15424 2001 PRIUS (RM778U) BO–35 BODY – FRONT WIPER AND WASHER BO3PT–01 INSTALLATION 1. (a) (b) 2. (a) INSTALL WASHER NOZZLES Install the washer nozzles to the hood. Connect the washer hoses. INSTALL OUTER FRONT COWL TOP PANEL Install the outer front cowl top panel with 6 bolts. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) (b) Push in the wiper motor wire harness with the grommet. 3. INSTALL ABS RELAY BLOCK Install the ABS relay block with the 2 bolts. 4. (a) Matchmarks (b) (c) INSTALL WIPER MOTOR Install the wiper motor with the 3 bolts to the wiper link. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) Align the matchmarks on the wiper link and wiper motor, then install the washer and nut. Torque: 17 N·m (175 kgf·cm, 13 ft·lbf) Install the wiper motor cover. H15398 5. (a) H15396 2001 PRIUS (RM778U) INSTALL WIPER LINK ASSEMBLY Install the wiper link assembly with 5 bolts. Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf) (b) Connect the connecter. 6. INSTALL COWL TOP VENTILATOR LOUVERS Install the cowl top ventilator louver LH and RH, then install the 2 screws. 7. INSTALL HOOD TO COWL TOP SEAL 8. INSTALL WIPER ARMS (a) Operate the wiper motor once and turn the wiper switch OFF. (b) Install the wiper arms and tighten nuts by hand. BO–36 BODY (c) (d) (e) Point Marks 2001 PRIUS (RM778U) H15399 – FRONT WIPER AND WASHER Adjust the installation position of the arms to the positions as shown in the illustration. Torque the 3 nuts. Torque: 26 N·m (270 kgf·cm, 20 ft·lbf) Install the wiper arm head cap. BO–39 BODY – ROOF DRIP SIDE FINISH MOULDING BO3PW–01 INSTALLATION 1. (a) CLEAN CONTRACT SURFACE OF BODY Using a heat light, heat the moulding surface to 40 – 60 °C (104 – 140 °F). NOTICE: Do not heat the body excessively. (b) Using a knife, cut away any rough areas on the body. NOTICE: Be careful not to damage the body. (c) Wipe off stains with cleaner. 2. CLEAN MOULDING If reusing the moulding. (a) Using a heat light, heat the moulding surface to 20 – 30 °C (68 – 86 °F). NOTICE: Do not heat the moulding excessively. (b) Using a knife, cut the remaining adhesive from the moulding. NOTICE: Be careful not to damage the moulding. (c) Wipe off stains with cleaner. 3. Primer M B A Primer M H13671 2001 PRIUS (RM778U) COAT CONTACT SURFACE OF BODY WITH PRIMER ”M” Using a brush, coat the contact surface on the body with Primer M as shown in the illustration. Front end: A: 24.9 mm (0.980 in.) B: 47.5 mm (1.870 in.) Rear end: A: 23.2 mm (0.913 in.) B: 57.5 mm (2.264 in.) NOTICE:
Let the primer coating dry for 3 minutes or more.
Do not coat the adhesive.
Do not keep any of the opened Primer M for later use. BO–40 BODY 4. (a) ROOF DRIP SIDE FINISH MOULDING APPLY ADHESIVE Cut off the tip of the cartridge nozzle. Part No. 08850–00801 or equivalent HINT: After cutting off the tip, use all adhesive within the time described in the chart below. Adhesive C 5.0 mm (0.197 in.) (b) (c) Adhesive 5.0 mm (0.197 in.) Primer M H13672 2001 PRIUS (RM778U) – Temperature Tackfree time 35 °C (95 °F) 15 minutes 20 °C (68 °F) 100 minutes 5 °C (41 °F) 8 hours Load the cartridge into the sealer gun. Apply adhesive to the hatched area in the illustration for both front and rear of the vehicle. C: 20 mm (0.79 in.) HINT: When removing the moulding, apply adhesive well to the part where the body sealer is removed. 5. INSTALL MOULDING Push the moulding to the body. NOTICE:
Make sure that the body and moulding are heated to the proper temperature.
Do not depress the adhesive coated parts excessively but just hold them down with your thumb.
Scrape off any overflowing adhesive with a plastic spatula and clean the surface with a dry rag.
Take care not to drive the vehicle during the time described in the chart below. Temperature Minimum time prior to driving the vehicle 35 °C (95 °F) 1.5 hours 20 °C (68 °F) 5 hours 5 °C (41 °F) 24 hours BO–45 BODY – WINDSHIELD BO3PY–01 REMOVAL 2 Clips 1. H13603 REMOVE FRONT PILLAR GARNISH AND NO. 1 FRONT PILLAR SPACERS Using a screwdriver, remove the front pillar garnish. (a) HINT: Tape the screwdriver tip before use. (b) Remove the 4 screws and 2 No. 1 front pillar spacers. (c) Employ the same manner described above to the other side. 2. (a) REMOVE INNER REAR VIEW MIRROR Using a moulding remover, remove the cover as shown in the illustration. H15356 H15357 2001 PRIUS (RM778U) (b) Remove the 2 screws and inner rear view mirror. 3. REMOVE MAP LAMP (a) Using a screwdriver, remove the map lamp. (b) Disconnect the connector. 4. REMOVE SUN VISORS Remove the 4 screws and pull the 2 sun visors downward. 5. REMOVE SUN VISOR HOLDERS Remove the 2 screws and 2 holders. 6. REMOVE ASSIST GRIP (a) Using a screwdriver, remove the caps. HINT: Tape the screwdriver tip before use. (b) Remove the 2 screws and assist grip. 7. PULL DOWN FRONT PART OF ROOF HEADLINING 8. REMOVE WIPER ARMS Remove the wiper arm head cap, 3 nuts and 2 wiper arms. 9. REMOVE HOOD TO COWL TOP SEAL 10. REMOVE COWL TOP VENTILATOR LOVERS Remove the 2 screws, then pull out the cowl top ventilator louver RH and LH. BO–46 BODY w/o Rain garter: Windshield Glass Windshield Moulding Body w/ Rain garter: – WINDSHIELD 11. REMOVE WINDSHIELD MOULDING (a) Using a knife, cut off the moulding as shown. NOTICE: Do not damage the body with the knife. (b) Remove the remaining moulding. Windshield Moulding Windshield Glass Body H15403 12. (a) Protective Tape Body Windshield Glass REMOVE WINDSHIELD GLASS Push piano wire through between the body and glass from the interior. Tie both wire ends to wooden blocks or similar object. (b) HINT: Apply protective tape to the outer surface to keep the surface from being scratched. BO5232 NOTICE: When separating the glass, be careful not to damage the paint and interior and exterior ornaments. To prevent scratching the safety pad when removing the windshield, place a plastic sheet between the piano wire and safety pad. Plastic Sheet Protective Tape BO1689 2001 PRIUS (RM778U) BO–47 BODY – WINDSHIELD BO3PZ–01 INSTALLATION Body Adhesive BO4420 1. CLEAN AND SHAPE CONTACT SURFACE OF BODY (a) Using a knife, cut away any rough areas on the body. HINT: Leave as much of the adhesive on the body as possible. (b) Clean the cutting surface of the adhesive with a shop rag saturated in cleaner. HINT: Even if all the adhesive has been removed, clean the body. 2. (a) CLEAN REMOVED GLASS Using a scraper, remove the damaged stoppers, dam and adhesive sticking to the glass. (b) Clean the glass with cleaner. NOTICE:
Do not touch the glass face after cleaning it.
Be careful not to damage the glass. BO5231 3. INSTALL NEW STOPPERS Install new stoppers onto the glass. A: 9.5 mm (0.374 in.) A A Stopper H15404 4. INSTALL NEW DAM Install a new dam with adhesive tape as shown in the illustration. A: 7.0 mm (0.276 in.) a a a a b b a–a A b–b Along Datum Line H12696 2001 PRIUS (RM778U) BO–48 BODY 5. (a) (b) (c) (d) Reference Marks – WINDSHIELD POSITION GLASS Using a suction rubber, place the glass in the correct position. Check that all contacting parts of the glass rim are perfectly even. Place reference marks between the glass and body. Remove the glass. BO2821 6. CLEAN CONTACT SURFACE OF GLASS Using a cleaner, clean the contact surface which is black–colored area around the entire glass rim. NOTICE: Do not touch the glass face after cleaning it. BO4421 7. Primer M COAT CONTACT SURFACE OF BODY WITH PRIMER ”M” Using a brush, coat Primer M to the exposed part of body on the vehicle side. NOTICE:
Let the primer coating dry for 3 minutes or more.
Do not coat Primer M to the adhesive.
Do not keep any of the opened Primer M for later use. Primer M Primer M Adhesive Primer G H02865 8. Primer G Dam H00471 2001 PRIUS (RM778U) COAT CONTACT SURFACE OF GLASS WITH PRIMER ”G” (a) Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G. (b) When the primer is coated wrongly to the area other than the specified, wipe it off with a clean shop rag before the primer dries. NOTICE:
Let the primer coating dry for 3 minutes or more.
Do not keep any of the opened Primer G for later use. 9. APPLY ADHESIVE (a) Cut off the tip of the cartridge nozzle. Part No. 08850–00801 or equivalent BO–49 BODY – WINDSHIELD HINT: After cutting off the tip, use all adhesive within the time described in the table below. Temperature Tackfree time 35 °C (95 °F) 15 minutes 20 °C (68 °F) 100 minutes 5 °C (41 °F) 8 hours (b) Load the cartridge into the sealer gun. (c) Coat the glass with adhesive as shown. A: 12 mm (0.47 in.) B: 8 mm (0.31 in.) 10. (a) INSTALL WINDSHIELD GLASS AND MOULDING Install the glass, aligning the reference marks using a suction rubber. Adhesive A Dam B H00464 HINT: Check to see that the stoppers are attached to the body correctly. (b) Lightly press the glass front surface for close contact. Reference Marks BO2821 (c) Windshield Glass Correct insufficient or protruded adhesive agent using a spatula. HINT: Apply the adhesive agent up to the windshield glass edge. Adhesive 2001 PRIUS (RM778U) H00679 BO–50 BODY (d) w/o Rain garter: Windshield Moulding Windshield Glass Body w/ Rain garter: Windshield Moulding Body 2001 PRIUS (RM778U) H15399 Install a new windshield moulding to the windshield glass before the adhesive agent hardens. Temperature Minimum time prior to driving the vehicle 35 °C (95 °F) 1.5 hours 20 °C (68 °F) 5 hours 5 °C (41 °F) 24 hours 11. INSPECT FOR LEAK AND REPAIR NOTICE: Conduct a leak test after the hardening time has elapsed. 12. INSTALL COWL TOP VENTILATOR LOUVERS Install the cowl top ventilator louver LH and RH, then install the 2 screws. 13. INSTALL HOOD TO COWL TOP SEAL 14. INSTALL WIPER ARMS (a) Operate the wiper motor once and turn the wiper switch OFF. (b) Install the wiper arms and tighten nuts by hand. (c) Point Marks WINDSHIELD HINT: Install the moulding, aligning the center of moulding with the center of body. (e) Remove any excessive adhesive agent before it hardens. (f) Hold the glass and moulding in place securely with a protective tape or equivalent until the adhesive hardenes. NOTICE: Take care not to drive the vehicle during the time described in the table below. Windshield Glass H15405 – Adjust the installation positions of the wiper arms to the positions as shown in the illustration. (d) Torque the 3 nuts. Torque: 26 N·m (270 kgf·cm, 20 ft·lbf) (e) Install the wiper arm head cap. 15. INSTALL FRONT SIDE OF ROOF HEADLINING 16. INSTALL ASSIST GRIP (a) Install the assist grip with the 2 screws. (b) Install the caps. 17. INSTALL SUN VISOR HOLDERS Install the 2 sun visor holders with the 2 screws. 18. INSTALL SUN VISORS Install the 2 sun visors with the 4 screws. 19. INSTALL MAP LAMP (a) Connect the connector. (b) Install the map lamp. BO–51 BODY 20. (a) (b) – WINDSHIELD INSTALL INNER REAR VIEW MIRROR Install the inner rear view mirror with the 2 screws. Torque: 2.9 N·m (30 kgf·cm, 26 in.·lbf) Install the cover. H15357 21. 2 Clips (a) (b) (c) H13603 2001 PRIUS (RM778U) INSTALL FRONT PILLAR GARNISH AND NO. 1 FRONT PILLAR SPACERS Install the 2 No. 1 front pillar spacers and 4 screws. Install the front pillar garnish to the body. Employ the same manner described above to the other side. BO–53 BODY – BACK WINDOW GLASS BO3Q1–01 REMOVAL 1. 2. 3. REMOVE REAR SEAT CUSHION (See page BO–83) REMOVE REAR SEATBACK (See page BO–83) REMOVE UPPER PART OF REAR DOOR OPENING TRIMS 4. REMOVE ROOF SIDE INNER GARNISH (a) Using a screwdriver, disengage the clips. HINT: Tape the screwdriver tip before use. (b) Pull the garnish upward to remove it. (c) Employ the same manner described above to the other side. 5 Clips H13694 5. (a) REMOVE HIGH–MOUNTED STOP LIGHT Remove the clip, then pull the high–mounted stop light cover. (b) Disconnect the connector. (c) Remove the 2 screws and high–mounted stop light. 6. REMOVE CRS TETHER ANCHORS Remove the 3 CRS tether anchor covers and 3 CRS tether anchor brackets. H15383 7. (a) 4 Clips (b) H15384 2001 PRIUS (RM778U) REMOVE PACKAGE TRAY TRIM PANEL Pull the package tray trim panel upward to disengage the clips. Remove the rear seat outer belts through the cutout on the package tray trim. Pull the package tray trim panel forward to remove it. REMOVE SILENCER PAD REMOVE REAR ASSIST GRIPS Using a screwdriver, remove the caps. (c) 8. 9. (a) HINT: Tape the screwdriver tip before use. (b) Remove the 4 screws and 2 rear assist grips. 10. PULL DOWN REAR PART OF ROOF HEADLINING Remove the 2 clips. BO–54 BODY – BACK WINDOW GLASS 11. (a) REMOVE BACK WINDOW OUTSIDE MOULDING Using a knife, cut off the moulding as shown in the illustration. NOTICE: Do not damage the body with the knife. (b) Remove the remaining moulding. H15378 Protective Tape H15379 Protective Tape 12. REMOVE BACK WINDOW GLASS (a) Disconnect the connector. (b) Push piano wire through from the interior. (c) Tie both wire ends to wooden blocks or similar objects HINT: Apply protective tape to the outer surface to keep the surface from being scratched. NOTICE: When separating the glass, take care not to damage the paint and exterior. (d) Cut the adhesive by pulling the piano wire around it. HINT: Cut the adhesive areas as shown in the illustration, leaving the adhesive where the stoppers are. H15380 (e) Let the piano wire pass as shown in the illustration, cut off the adhesive sticking to the stoppers. NOTICE:
Do not damage the glass stoppers.
Leave as much of the adhesive on the body as possible when cutting off the glass. H07610 2001 PRIUS (RM778U) BO–55 BODY – BACK WINDOW GLASS BO3Q2–01 INSTALLATION Adhesive BO4420 1. CLEAN AND SHAPE CONTACT SURFACE OF BODY (a) Using a knife, cut away any rough areas on the body. HINT: Leave as much of the adhesive on the body as possible. (b) Clean the cutting surface of the adhesive with a piece of shop rag saturated in cleaner. HINT: Even if all the adhesive has been removed, clean the body. 2. (a) CLEAN REMOVED GLASS Using a scraper, remove the adhesive sticking to the glass. (b) Clean the glass with cleaner. NOTICE:
Be careful not to damage the glass.
Do not touch the glass face after cleaning it. BO5231 3. INSTALL NEW STOPPERS Install new stoppers onto the glass. A: 7.0 mm (0.276 in.) A A Stopper H15381 4. INSTALL NEW BACK WINDOW OUTSIDE MOULDING Install new back window outside moulding to the back window glass as shown in the illustration. HINT:
Install the back window outside moulding from the center of the glass at the lower side of the vehicle.
When installing the back window outside moulding, do not stretch it. Connected Portion H15382 2001 PRIUS (RM778U) BO–56 BODY 5. (a) (b) (c) (d) Reference Marks – BACK WINDOW GLASS POSITION GLASS Place the glass in the correct position. Check that all contacting parts of the glass rim are perfectly even. Place reference marks between the glass and body. Remove the glass. H10504 6. CLEAN CONTACT SURFACE OF GLASS Using a cleaner, clean the contact surface which is black–colored area around the entire glass rim. NOTICE: Do not touch the glass face after cleaning it. BO4421 7. COAT CONTACT SURFACE OF BODY WITH PRIMER ”M” Using a brush, coat Primer M to the exposed part of body on the vehicle side. NOTICE:
Let the primer coating dry for 3 minutes or more.
Do not coat Primer M to the adhesive.
Do not keep any of the opened Primer M for later use. Primer M Primer M Adhesive H02865 8. a a b b b b a–a b–b Primer G H15385 2001 PRIUS (RM778U) COAT CONTACT SURFACE OF GLASS WITH PRIMER ”G” (a) Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G as shown in the illustration. (b) When the primer is coated wrongly to the area other than the specified, wipe it off with a clean shop rag before the primer dries. NOTICE:
Let the primer coating dry for 3 minutes or more.
Do not keep any of the opened Primer G for later use. BO–57 BODY a 9. (a) a b b b b–b A A BACK WINDOW GLASS APPLY ADHESIVE Cut off the tip of the cartridge nozzle. Part No. 08850–00801 or equivalent HINT: After cutting off the tip, use all adhesive within the time described in the table below. b a–a – Temperature Tackfree time 35°C (95°F) 15 minutes 20°C (68°F) 100 minutes 5°C (41°F) 8 hours (b) (c) Load the cartridge into the sealer gun. Coat the glass with adhesive as shown in the illustration. A: 12 mm (0.47 in.) B: 8 mm (0.31 in.) 10. (a) INSTALL GLASS Position the glass so that the reference marks are lined up, and press in gently along the rim. B B Adhesive H15386 Reference Marks H10505 HINT: Confirm that the moulding is attached to the body panel as shown in the illustration. (b) Hold the back window glass in place securely with a protective tape or equivalent until the adhesive hardens. NOTICE: Take care not to drive the vehicle during the time described in the table below. H15387 11. (a) (b) 2001 PRIUS (RM778U) Temperature Minimum time prior to driving the vehicle 35°C (95°F) 1.5 hours 20°C (68°F) 5 hours 5°C (41°F) 24 hours INSPECT FOR LEAK AND REPAIR Conduct a leak test after the hardening time has elapsed. Seal any leak with sealant. Part No. 08833–00030 or equivalent BO–58 BODY – BACK WINDOW GLASS 12. INSTALL REAR PART OF ROOF HEADLINING Install the 2 clips. 13. INSTALL REAR ASSIST GRIPS (a) Install the 2 rear assist grips with the 4 screws. (b) Install the caps. 14. INSTALL SILENCER PAD 15. (a) 4 Clips (b) 16. (a) (b) INSTALL PACKAGE TRAY TRIM PANEL Install the seat belt through the cutout of the package tray trim. Install the package tray trim as shown in the illustration. INSTALL CRS TETHER ANCHORS Install the 3 CRS tether anchor brackets. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) Install the CRS tether anchor covers. H15384 17. (a) (b) (c) INSTALL HIGH–MOUNTED STOP LIGHT Install the high–mounted stop light with the 2 screws. Connect the connector. Install the high–mounted stop light cover, then install the clip. 18. (a) INSTALL ROOF SIDE INNER GARNISH Install the roof side inner garnish as shown in the illustration. Employ the same manner described above to the other side. INSTALL UPPER PART OF REAR DOOR OPENING TRIMS INSTALL REAR SEATBACK (See page BO–86) INSTALL REAR SEAT CUSHION (See page BO–86) H15383 5 Clips (b) 19. H13694 2001 PRIUS (RM778U) 20. 21. BO–59 BODY – INSTRUMENT PANEL INSTRUMENT PANEL BO3TB–01 COMPONENTS Combination Meter Passenger Airbag Assembly Cluster Finish Panel Front Pillar Garnish No. 1 Side Defroster Nozzle Front Pillar Garnish No. 2 Side Defroster Nozzle B No. 3 Register B N N Instrument Panel C H w/ Glove compartment door reinforcement: Glove Compartment Door Reinforcement A H L 20 (204, 15) No. 1 Register A G D D I G Upper Column Cover Instrument Panel Reinforcement G L G G G I Hazard Warning Switch No. 1 Brace Cluster Finish Panel Assembly D D Finish Panel Steering Wheel Pad Radio Tuner Opening Cover K K E 50 (510, 37) Spiral Cable Lower Center Cluster Finish Panel Lower Column Cover I O E L L Glove Compartment Door Steering Wheel Lower Finish Panel H H Cowl Side Trim Console Compartment Door Hood Lock Release Lever F Cowl Side Trim F Front Door Scuff Plate Front Door Scuff Plate N·m (kgf·cm, ft·lbf) : Spesified torque Rear Console Box H15446 2001 PRIUS (RM778U) Author: Date: 1844 BO–60 BODY – Defroster Nozzle INSTRUMENT PANEL No. 2 Side Defroster Nozzle J J J J J J No. 2 Side Defroster Nozzle J J No. 1 Heater to Register Duct J J J J No. 2 Instrument Panel Cushion J Navigation Antenna No. 3 Instrument Panel Cushion No. 4 Instrument Panel Cushion M No. 1 Pin No. 1 Instrument Panel Cushion M No. 1 Pin Fuse Box Opening Cover Instrument Panel Wire J Center Bracket M M M M M M M No. 1 Safty Pad M M M M M M No. 2 Safty Pad H15447 2001 PRIUS (RM778U) Author: Date: 1845 BO–61 BODY – INSTRUMENT PANEL HINT: Screw shapes and sizes are indicated in the table below. The codes (”A” – ”O”) correspond to those indicated on the previous pages. mm (in.) Shape Size Shape Size Shape Size ø=6 (0.24) L = 20 (0.79) ø=6 (0.24) L = 20 (0.79) ø=6 (0.24) L = 20 (0.79) ø=8 (0.31) L = 20 (0.79) ø=4 (0.16) L = 13 (0.51) ø=6 (0.24) L = 20 (0.79) ø=8 (0.31) ø = 5.22 (0.2055) L = 16 (0.63) ø=6 (0.24) L = 22 (0.87) ø=5 (0.20) L = 14 (0.55) ø=5 (0.20) L = 16 (0.63) ø=5 (0.20) L = 18 (0.71) ø=5 (0.20) L = 14 (0.55) ø=6 (0.24) ø=5 (0.20) L = 14 (0.55) H15475 2001 PRIUS (RM778U) Author: Date: 1846 BO–62 BODY – INSTRUMENT PANEL BO3TC–01 REMOVAL 1. 2. 3. 4. 5. (a) (b) (c) (d) (e) 3 Clips H15437 6. 7. 8. 9. (a) (b) (c) 10. (a) (b) 4 Clips H15438 H15519 2001 PRIUS (RM778U) REMOVE STEERING WHEEL PAD AND STEERING WHEEL (See page SR–4) REMOVE FRONT DOOR SCUFF PLATES REMOVE COWL SIDE TRIMS REMOVE FRONT PILLAR GARNISHES REMOVE LOWER FINISH PANEL Remove the 2 screws and hood lock release lever. Zip the shifting hole cover open. Remove the bolt and screw. Using a screwdriver, remove the lower finish panel, then disconnect the connectors and DLC3. Remove the shifting hole cover from the lower finish panel. REMOVE FINISH PANEL REMOVE COLUMN COVERS (See page SR–4) REMOVE SPIRAL CABLE (See page SR–4) REMOVE GLOVE COMPARTMENT DOOR Rotate the stoppers of the glove compartment door to 90° and pull them out inward. Remove the 2 screws and glove compartment door. Remove the 2 screws and glove compartment door lock from the glove compartment door. REMOVE LOWER CENTER CLUSTER FINISH PANEL Remove the 2 clips. Using a screwdriver, remove the lower center cluster finish panel. HINT: Tape the screwdriver tip before use. (c) Disconnect the connector. 11. w/ Glove compartment door reinforcement: REMOVE GLOVE COMPARTMENT DOOR REINFORCEMENT 12. DISCONNECT PASSENGER AIRBAG CONNECTOR (a) Disconnect the passenger airbag connector. NOTICE: When disconnecting the airbag connector, take care not to damage the airbag wire harness. (b) Disengage the airbag connector clamp from the center bracket. BO–63 BODY 13. (a) – INSTRUMENT PANEL REMOVE PASSENGER AIRBAG ASSEMBLY Remove the 2 bolts. Torque: 20 N·m (204 kgf·cm, 15 ft·lbf) H15508 (b) Remove the 2 nuts and passenger airbag assembly. CAUTION:
Do not store the passenger airbag assembly with the airbag deployment side facing down.
Never disassemble the passenger airbag assembly. NOTICE: When removing the passenger airbag assembly, take care not to damage the wire harness. H15509 14. REMOVE HAZARD WARNING SWITCH (a) Using a screwdriver, remove the hazard warning switch. HINT: Tape the screwdriver tip before use. (b) Disconnect the connectors. 2 Clips H15439 15. (a) (b) (c) 16. 6 Clips H15440 17. REMOVE COMBINATION METER (a) Using a screwdriver, remove the cluster finish panel. HINT: Tape the screwdriver tip before use. (b) Remove the 3 screws and combination meter. (c) Disconnect the connector. 2 Clips H15441 2001 PRIUS (RM778U) REMOVE CLUSTER FINISH PANEL ASSEMBLY Remove the 2 screws. Using a screwdriver, remove the cluster finish panel assembly. Disconnect the connectors. REMOVE RADIO OR RADIO TUNER OPENING COVER BO–64 BODY – INSTRUMENT PANEL 18. REMOVE NO. 1 AND NO. 2 SIDE DEFROSTER NOZZLES Using a screwdriver, remove the No. 1 and No. 2 side defroster nozzles. HINT: Tape the screwdriver tip before use. RH Side: LH Side: H15442 H15443 19. REMOVE NO. 1 AND NO. 3 REGISTERS Using a screwdriver, remove the No. 1 and No. 3 registers as shown in the illustration. HINT: Tape the screwdriver tip before use. 20. REMOVE STEERING COLUMN (See page SR–4) 21. REMOVE INSTRUMENT PANEL (a) Disconnect the connectors. (b) Disengage the wire harness clamps. (c) Remove the 4 bolts, 3 screws and instrument panel. H15444 2001 PRIUS (RM778U) BO–65 BODY – INSTRUMENT PANEL 22. REMOVE NO. 1 BRACE 23. REMOVE INSTRUMENT PANEL REINFORCEMENT Remove the 2 bolts, 4 nuts and instrument panel reinforcement. 24. REMOVE REAR CONSOLE BOX (a) Remove the 3 bolts and rear console box. (b) Remove the 2 screws and console compartment door from the rear console box. 2001 PRIUS (RM778U) BO–70 BODY – ROOF HEADLINING BO3SR–01 REMOVAL 1. 2. REMOVE REAR SEAT CUSHION (See page BO–83) REMOVE REAR SEATBACK (See page BO–83) 3. (a) REMOVE FRONT DOOR INSIDE SCUFF PLATE Using a screwdriver, remove the front door inside scuff plate. HINT: Tape the screwdriver tip before use. (b) Employ the same manner described above to the other side. H13689 4. (a) REMOVE REAR DOOR INSIDE SCUFF PLATE Using a screwdriver, remove the rear door inside scuff plate. HINT: Tape the screwdriver tip before use. (b) Employ the same manner described above to the other side. H13690 5. (a) (b) 6. 7. REMOVE COWL SIDE TRIM Remove the clip and cowl side trim. Employ the same manner described above to the other side. REMOVE FRONT DOOR OPENING TRIMS REMOVE REAR DOOR OPENING TRIMS H15374 8. (a) 2 Clips REMOVE CENTER PILLAR LOWER GARNISH Using a screwdriver, remove the center pillar lower garnish. HINT: Tape the screwdriver tip before use. (b) Employ the same manner described above to the other side. H13691 2001 PRIUS (RM778U) BO–71 BODY 9. H13692 Clip – ROOF HEADLINING REMOVE FRONT SEAT OUTER BELT SHOULDER ANCHOR Using a screwdriver, remove the anchor cover cap. (a) HINT: Tape the screwdriver tip before use. (b) Remove the bolt and front seat outer belt shoulder anchor. Torque: 42 N·m (430 kgf·cm, 31 ft·lbf) (c) Employ the same manner described above to the other side. 10. REMOVE CENTER PILLAR GARNISH (a) Using a screwdriver, remove the center pillar garnish. HINT: Tape the screwdriver tip before use. (b) Employ the same manner described above to the other side. H13693 11. REMOVE ROOF SIDE INNER GARNISH (a) Using a screwdriver, remove the roof side inner garnish. HINT: Tape the screwdriver tip before use. (b) Employ the same manner described above to the other side. 5 Clips H13694 12. 2 Clips REMOVE FRONT PILLAR GARNISH AND NO. 1 FRONT PILLAR SPACERS Using a screwdriver, remove the front pillar garnish. (a) HINT: Tape the screwdriver tip before use. (b) Remove the 4 screws and 2 No. 1 front pillar spacers. (c) Employ the same manner described above to the other side. H13603 13. REMOVE ROOM LIGHT ASSEMBLY (a) Using a screwdriver, remove the lens. HINT: Tape the screwdriver tip before use. (b) Remove the 2 screws and room light assembly. (c) Disconnect the connector. H15355 2001 PRIUS (RM778U) BO–72 BODY – ROOF HEADLINING 14. (a) REMOVE INNER REAR VIEW MIRROR Using a moulding remover, remove the cover as shown in the illustration. (b) Remove the 2 screws and inner rear view mirror. Torque: 2.9 N·m (30 kgf·cm, 26 in.·lbf) REMOVE MAP LAMP Using a screwdriver, remove the map lamp. Disconnect the map lamp connector. REMOVE ASSIST GRIPS Using a screwdriver, remove the caps. H15356 H15357 H15383 P 15. (a) (b) 16. (a) HINT: Tape the screwdriver tip before use. (b) Remove the 6 bolts and 3 assist grips. 17. REMOVE HIGH–MOUNTED STOP LIGHT (a) Remove the clip then pull the high–mounted stoplight cover. (b) Disconnect the connector. (c) Remove the 2 screws and high–mounted stop light. 18. REMOVE SUN VISORS (a) Remove the 4 screws and pull the sun visors downward. (b) Disconnect the connectors. 19. REMOVE SUN VISOR HOLDERS Remove the 2 screws and 2 holders. 20. REMOVE ROOF HEADLINING (a) Remove the 2 clips. (b) Pull the roof headlining downward to remove it. H15358 21. (a) (b) (c) P 2001 PRIUS (RM778U) H15359 REMOVE FRONT AND REAR SIDE RAIL SPACER Remove the 4 screws and front side rail spacer. Remove the 4 screws and rear side rail spacer. Employ the same manner described above to the other side. BO–76 BODY – FRONT SEAT BO3SV–01 DISASSEMBLY CAUTION:
When storing the seatback frame with the side airbag assembly, do not face down the airbag deployment side.
Never disassemble the side airbag assembly. 1. REMOVE HEADREST 2. REMOVE RECLINING RELEASE HANDLE A B H15461 3. REMOVE SEAT CUSHION SHIELD Remove the 2 screws and seat cushion shield as shown in the illustration. HINT: Remove the seat cushion shield in order A, B as shown in the illustration. 4. REMOVE FRONT SEAT INNER BELT Remove the bolt and front seat inner belt. 5. REMOVE SEAT CUSHION INNER SHIELD Remove the 2 screws and seat cushion inner shield. 6. w/o Side airbag: REMOVE SEATBACK ASSEMBLY Remove the 4 bolts and seatback assembly. H15368 7. (a) (b) (c) w/ Side airbag: REMOVE SEATBACK ASSEMBLY Remove the clamp from wire harness of side airbag installed under the seat, then pull out the wire harness. Remove the side airbag connector from the under the seat. Remove the 4 bolts and seatback assembly. H15458 Hog Ring 8. (a) (b) (c) (d) H15369 2001 PRIUS (RM778U) w/o Side airbag: REMOVE SEATBACK COVER Remove the hog rings. Remove the headrest supports. Remove the seatback cover with pad from the seatback frame. Remove the seatback cover from the seatback pad. BO–77 BODY 9. (a) (b) (c) (d) (e) – FRONT SEAT w/ Side airbag: REMOVE SEATBACK COVER Remove the hog rings. Remove seatback cover hook. Remove the headrest supports. Remove the seat back cover with pad from the seatback frame. Remove the seatback cover from the seatback pad. H15413 Hog Ring 10. (a) (b) 11. (a) (b) Hog Ring Hog Ring REMOVE SEAT CUSHION COVER WITH PAD Remove the hog rings. Disengage the seat cushion cover hooks and remove the seat cushion cover with pad from the seat cushion frame. REMOVE SEAT CUSHION COVER Remove the hog rings. Remove the seat cushion cover from the seat cushion pad. H15370 12. REMOVE RECLINING ADJUSTER INSIDE COVERS Remove the 2 screws and 2 reclining adjuster inside covers. 13. REMOVE SEAT TRACK HANDLE H15371 2001 PRIUS (RM778U) BO–79 BODY – FRONT SEAT BO3SW–01 REASSEMBLY NOTICE: If the seatback frame with the side airbag assembly has been dropped, or there are cracks, dents or other defects in the case or connector of the side airbag assembly, replace the seatback frame with a new one. H15371 Hog Ring Hog Ring 1. INSTALL SET TRACK HANDLE 2. INSTALL RECLINING ADJUSTER INSIDE COVERS Install the 2 screws and 2 reclining adjuster inside covers. 3. INSTALL SEAT CUSHION COVER Install the seat cushion cover with new hog rings to seat cushion pad. HINT: When installing hog rings, take care to prevent wrinkles as little as possible. 4. INSTALL SEAT CUSHION COVER WITH PAD Install the seat cushion cover with pad to the seat cushion frame with new hog rings. HINT: When installing hog rings, take care to prevent wrinkles as little as possible. Hog Ring H15370 5. Hog Ring (a) (b) (c) w/o Side airbag: INSTALL SEATBACK COVER Install the seatback cover with new hog rengs to the seatback pad. Install the seatback cover with pad to the seatback frame with new hog ring. Install the headrest supports. H15369 6. H15413 2001 PRIUS (RM778U) w/ Side airbag: INSTALL SEATBACK COVER (a) Install the seatback cover with new hog rengs to the seatback pad. (b) Install the seatback cover with pad to the seatback frame with new hog rings. (c) Install the seatback cover hook. CAUTION: Take care to hung the hook securely. Otherwise the seat cover slides, it might cause incorrect deploying. BO–80 BODY (d) – FRONT SEAT Install the headrest supports. 7. w/o Side airbag: INSTALL SEATBACK ASSEMBLY Install seatback assembly with 4 bolts. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) H15368 8. H15458 B A H15461 2001 PRIUS (RM778U) w/ Side airbag: INSTALL SEATBACK ASSEMBLY (a) Install the 4 bolts and seatback assembly. (b) Install the side airbag connector from the under the seat. (c) Install the clamp from wire harness of side airbag removed under the seat. 9. INSTALL SEAT CUSHION INNER SHIELD 10. INSTALL FRONT SEAT INNER BELT Install the front seat inner belt with the bolt. Torque: 41 N·m (420 kgf·cm, 30 ft·lbf) 11. INSTALL SEAT CUSHION SHIELD Install the 2 screws and seat cushion sushion shield as shown in the illustration. HINT: Install the seat cushion shield in order A, B as shown in the illustration. 12. INSTALL RECLINING RELEASE HANDLE 13. INSTALL HEADREST BO–88 BODY – SEAT BELT BO3T5–01 INSPECTION CAUTION: Replace the seat belt assembly (outer belt, inner belt, bolts, nuts or sill–bar) if it has been used in a severe impact. The entire assembly should be replaced even if damage is not obvious. 1. RUNNING TEST (IN SAFE AREA) (a) Fasten the front seat belts. (b) BO0632 45° BO0633 2001 PRIUS (RM778U) HINT: Conduct this test in a safe area. If the belt does not lock, remove the belt mechanism assembly and conduct the following static check. Also, whenever installing a new belt assembly, verify the proper operation before installation. 2. Driver’s seat belt (ELR): STATIC TEST (a) Make sure that the belt locks when pulled out quickly. (b) Remove the locking retractor assembly. (c) Tilt the retractor slowly. (d) 15° Drive the car at 10 mph (16 km/h) and slam on the brakes. Check that the belt locks and cannot be extended at this time. Make sure that belt can be pulled out at a tilt of 15 degrees or less, and cannot be pulled out over 45 degrees of tilt. lf a problem is found, replace the assembly. 3. Except driver’s seat belt (ALR/ELR): STATIC TEST (a) Make sure that the belt locks when pulled out quickly. (b) Remove the locking retractor assembly. (c) Pull out the whole belt and measure the length of the whole belt. Then retract the belt slightly and pull it out again. (d) Make sure that the belt cannot be extended further. If a problem is found,replace the assembly. BO–89 BODY (e) Full Belt Length Minus (f) – SEAT BELT Retract whole belt, then pull out the belt until 200 mm (7.87 in.) of belt remains retracted. Tilt the retractor slowly. 200 mm (7.87 in.) N10070 (g) Make sure that the belt can be pulled out at a tilt of 15 degrees or less, and cannot be pulled out at over 45 degrees of tilt. lf problem is found, replace the assembly. 15° 45° BO0633 2001 PRIUS (RM778U) BO–90 BODY – SEAT BELT PRETENSIONER SEAT BELT PRETENSIONER BO3T6–01 REMOVAL NOTICE:
If the wiring connector of the seat belt pretensioner is disconnected with the ignition switch at ON or ACC, diagnostic trouble codes will be recorded.
Never use seat belt pretensioner from another vehicle. When replacing parts, replace them with new parts. 1. REMOVE FRONT DOOR INSIDE SCUFF PLATE Using a screwdriver, remove the front door inside scuff plate. HINT: Tape the screwdriver tip before use. H13689 2. REMOVE REAR DOOR INSIDE SCUFF PLATE Using a screwdriver, remove the rear door inside scuff plate. HINT: Tape the screwdriver tip before use. 3. REMOVE FRONT DOOR OPENING TRIM 4. REMOVE REAR DOOR OPENING TRIM H13690 5. REMOVE CENTER PILLAR LOWER GARNISH Remove the center pillar lower garnish as shown in the illustration. 2 Clips H13691 H13692 6. REMOVE FRONT SEAT OUTER BELT (a) Using a screwdriver, remove the shoulder anchor cover. HINT: Tape the screwdriver tip before use. (b) Remove the bolt and shoulder anchor. (c) Using a screwdriver, remove the floor anchor cover. HINT: Tape the screwdriver tip before use. (d) Remove the bolt and floor anchor. 2001 PRIUS (RM778U) Author: Date: 1875 BO–91 BODY – SEAT BELT PRETENSIONER (e) Driver’s side: Remove the retractor of front seat outer belt. CAUTION: Never disassemble the front seat outer belt. NOTICE: When removing the retractor of front seat outer belt, take care not to pull the seat belt pretensioner wire harness. (1) H15467 H15471 Disconnect the pretensioner connector as shown in the illustration. Disconnect the tension reducer connector. (2) CAUTION: When removing the seat belt pretensioner, work must be started 90 seconds after the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery. NOTICE: When handling the pretensioner connector and tensionreducer, take care not to damage the harness. (3) Remove the bolts and retractor of front seat outer belt. (f) Except driver’s side: Remove the retractor of front seat outer belt. CAUTION: Never disassemble the front seat outer belt. NOTICE: When removing the retractor of front seat outer belt, take care not to pull the seat belt pretensioner wire harness. (1) Disconnect the pretensioner connector as shown in the illustration. CAUTION: When removing the seat belt pretensioner, work must be started 90 seconds after the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery. NOTICE: When handling the pretensioner connector and tensionreducer, take care not to damage the harness. (2) Remove the bolts and retractor of front seat outer belt. 2001 PRIUS (RM778U) Author: Date: 1876 BO–93 BODY – SEAT BELT PRETENSIONER BO3T8–01 DISPOSAL HINT: When scrapping vehicles equipped with a seat belt pretensioner or disposing of a front seat outer belt (with seat belt pretensioner) always first activate the seat belt pretensioner in accordance with the procedure described below. If any abnormality occurs in the seat belt pretensioner operation, contact the SERVICE DEPT. of the TOYOTA MOTOR SALES, USA, INC. CAUTION:
Never dispose of the front seat outer belt which has an inactivated pretensioner.
The seat belt pretensioner produces a sizeable exploding sound when it activates, so perform the operation out–of–door and where it will not create a nuisance to nearby residents.
SST
AB0152



1. Battery SST AB0158 2001 PRIUS (RM778U) When activating the seat belt pretensioner, always use the specified SST. (SRS Airbag Deployment Tool) Perform the operation in a place away from electrical noise. SST 09082–00700 When activating a front seat outer belt (with seat belt pretensioner), perform the operation at least 10 m (33 ft) away from the front seat outer belt. The front seat outer belt (with seat belt pretensioner) is very hot when the pretensioner is deployed, so leave it alone for at least 30 minutes after deployment. Use gloves and safety glasses when handling a front seat outer belt with activated pretensioner. Always wash your hands with water after completing the operation. Do not apply water, etc. to a front seat outer belt with the activated pretensioner. SEAT BELT PRETENSIONER ACTIVATION WHEN SCRAPPING VEHICLE HINT: Have a battery ready as the power source to activate the seat belt pretensioner. BO–94 BODY – SEAT BELT PRETENSIONER (a) Check the functioning of SST. CAUTION: When activating the seat belt pretensioner, always use the specified SST: SRS Airbag Deployment Tool. SST Driver’s side: 09082–00700, 09082–00730 Except driver’s side: 09082–00700, 09082–00740 SST AB0152 (1) Battery Connect the SST to the battery. Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (–) terminal. HINT: Do not connect the yellow connector which will be connected with the seat belt pretensioner. SST AB0158 (2) SST Press the SST activation switch, and check the LED of the SST activation switch lights up. CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is probable, so definitely do not use the SST. (3) Disconnect the SST from the battery. H01580 (b) Disconnect the pretensioner connector. Disconnect the pretensioner connector as shown in the illustration. NOTICE: When handling the pretensioner connector, take care not to damage the wire harness. (c) Install the SST. (1) Buckle the front seat belt and check that there is no looseness and slack in the front seat inner belt and front seat outer belt. Driver’s side: Except driver’s side: H15467 H15471 2001 PRIUS (RM778U) H16295 BO–95 BODY – (2) SEAT BELT PRETENSIONER Connect the 2 SST, then connect them to the seat belt pretensioner. SST Driver’s side: 09082–00700, 09082–00730 Except driver’s side: 09082–00700, 09082–00740 NOTICE: To avoid damaging the SST connector and wire harness. SST SST H15464 (3) 10 m (33 ft) or more R13455 2001 PRIUS (RM778U) Move the SST to at least 10 m (33 ft) away from the front of the vehicle. Close all the doors and windows of the vehicle. (4) NOTICE: Take care not to damage the SST wire harness. (5) Connect the SST red clip to the battery positive (+) terminal and the black clip to the negative (–) terminal. (d) Activate the seat belt pretensioner. (1) Confirm that no one is inside the vehicle or within 10 m (33 ft) area around the vehicle. (2) Press the SST activation switch and activate the seat belt pretensioner. HINT: The seat belt pretensioner operates simultaneously as the LED of the SST activation switch lights up. (e) Dispose of the front seat outer belt (with seat belt pretensioner). CAUTION:
The front seat outer belt is very hot when the seat belt pretensioner is activated, so leave it alone for at least 30 minutes after activation.
Use gloves and safety glasses when handling a front seat outer belt with the activated seat belt pretensioner.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a front seat outer belt with the activated seat belt pretensioner. HINT: When scrapping a vehicle, activate the seat belt pretensioner and scrap the vehicle with the activated front seat outer belt still installed. 2. ACTIVATION WHEN DISPOSING OF FRONT SEAT OUTER BELT ONLY NOTICE:
When disposing of the front seat outer belt (with seat belt pretensioner) only, never use the customer’s vehicle to activate the seat belt pretensioner. BO–96 BODY
– SEAT BELT PRETENSIONER Be sure to follow the procedure given on the next page when activating the seat belt pretensioner. HINT: Have a battery ready as the power source when activating the seat belt pretensioner. (a) Remove the front seat outer belt (See page BO–90). HINT: Cut the belt near the seat belt retractor. (b) Battery Check the functioning of SST. (See step 1–(a)) SST Driver’s side: 09082–00700, 09082–00730 Except driver’s side: 09082–00700, 09082–00740 SST AB0158 (c) Install the SST. (1) Connect the 2 SST, then connect them to the seat belt pretensioner. SST Driver’s side: 09082–00700, 09082–00730 Except driver’s side: 09082–00700, 09082–00740 NOTICE: To avoid damaging the SST connector and wire harness. SST SST H15464 (2) H15465 2001 PRIUS (RM778U) Place the front seat outer belt on the ground and cover it with the disc wheel with tire. NOTICE: Place the front seat outer belt as shown in the illustration. Also, secure some slack for the SST wire harness inside the tire. (3) Move the SST at least 10 m (33 ft) away from the disc wheel. NOTICE: Take care not to damage the SST wire harness. (d) Activate the seat belt pretensioner. (1) Connect the SST red clip to the battery positive (+) terminal and black clip to the battery negative (–) terminal. (2) Check that no one is within 10 m (33 ft) area around the disc wheel. (3) Press the SST activation switch and activate the seat belt pretensioner. BO–97 BODY – SEAT BELT PRETENSIONER HINT: The seat belt pretensioner operates simultaneously as the LED of the SST activation switch lights up. 10 m (33 ft) or more R05181 (e) H15466 2001 PRIUS (RM778U) Dispose of the front seat outer belt (with seat belt pretensioner). CAUTION:
The front seat outer belt is very hot when the seat belt pretensioner is activated, so leave it alone for at least 30 minutes after activation.
Use gloves and safety glasses when handling a front seat outer belt with the activated seat belt pretensioner.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a front seat outer belt with the activated seat belt pretensioner. (1) Remove the disc wheel and SST. (2) Place the front seat outer belt in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts dispose. BO–99 BODY – SEAT BELT PRETENSIONER BO3TA–01 INSTALLATION NOTICE:
Never use seat belt pretensioner from another vehicle. When replacing parts, replace them with new parts.
Make sure that the front seat outer belt is installed with the specified torque.
If the front seat outer belt has been dropped, or there are cracks, dents or other defects in the case or connector, replace the front seat outer belt with a new one.
When installing the front seat outer belt, take care that the wiring does not interfere with other parts and is not pinched between other parts. 1. (a) INSTALL FRONT SEAT OUTER BELT Install the retractor of front seat outer belt. (1) Install the retractor of front seat outer belt with the bolt. Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf) (2) Connect the pretensioner connector as shown in the illustration. (3) Connect the tension reducer connector. NOTICE: When handling the pretensioner connector and tensionreducer, take care not to damage the wire harness. (b) Install the floor anchor with the bolt. Torque: 42 N·m (430 kgf·cm, 31 ft·lbf) (c) Install the floor anchor cover. Driver’s side: Except driver’s side: H15467 H15360 H16310 (d) (e) H15375 2001 PRIUS (RM778U) Install the shoulder anchor with the bolt. Torque: 42 N·m (430 kgf·cm, 31 ft·lbf) Install the shoulder anchor cover. BO–100 BODY – SEAT BELT PRETENSIONER 2. INSTALL CENTER PILLAR LOWER GARNISH Install the center pillar lower garnish to the body. 3. INSTALL FRONT DOOR OPENING TRIM 4. INSTALL REAR DOOR OPENING TRIM 2 Clips H13691 5. INSTALL REAR DOOR INSIDE SCUFF PLATE Install the rear door inside scuff plate to the body. H13690 6. INSTALL FRONT DOOR INSIDE SCUFF PLATE Install the front door inside scuff plate to the body. H13689 2001 PRIUS (RM778U) AC–1 AIR CONDITIONING – AIR CONDITIONING SYSTEM AIR CONDITIONING SYSTEM AC0Y9–05 PRECAUTION 1. 2. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED AREA OR WEAR A NAKED FLAME ALWAYS WEAR EYE PROTECTION AC2810 3. AC2811 Wrong LO HI 6. Okay LO BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin. (a) Wash the area with lots of cool water. CAUTION: Do not rub your eyes or skin. (b) Apply clean petroleum jelly to the skin. (c) Go immediately to a physician or hospital for professional treatment. 4. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED FLAME 5. BE CAREFUL NOT TO DROP CONTAINER AND NOT TO APPLY PHYSICAL SHOCKS TO IT HI N11084 DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERATION SYSTEM If there is not enough refrigerant in the refrigerant system oil lubrication will be insufficient and compressor burnout may occur, so that care to avoid this, necessary care should be taken. 7. DO NOT OPEN PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATE If the high pressure valve is opened, refrigerant flows in the reverse direction and could cause the charging cylinder to rupture, so open and close the only low pressure valve. 8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine overheating etc. 2001 PRIUS (RM778U) Author: Date: 1889 AC–2 AIR CONDITIONING – AIR CONDITIONING SYSTEM 9. SUPPLEMENTAL RESTRAINT SYSTEM (SRS) The PRIUS is equipped with an SRS (Supplemental Restraint System) such as the driver, front passenger and side airbag. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing ( including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices in the RS section. 2001 PRIUS (RM778U) Author: Date: 1890 AC–3 AIR CONDITIONING – AIR CONDITIONING SYSTEM AC0YB–04 ON–VEHICLE INSPECTION ight Glass I17971 Item 1. INSPECT REFRIGERANT VOLUME Observe the sight glass on the liquid tube. Test conditions:  MAX. switch ON  Blower speed control set at ”HI”  Temperature control set at ”MAX. COOL”  Running engine at 1,500 rpm  Fully open the doors Symptom Amount of refrigerant Remedy 1 Bubbles present in sight glass Insufficient* (1) Check for gas leakage with gas leak detector and repair if necessary (2) Add refrigerant until bubbles disappear 2 No bubbles present in sight glass None, sufficient or too much Refer item 3 and 4 3 No temperature difference between compressor inlet and outlet Empty or nearly empty (1) Check for gas leakage with gas leak detector and repair if necessary (2) Add refrigerant until bubbles disappear 4 Temperature between compressor inlet and outlet is noticeably different Correct or too much Refer to items 5 and 6 5 Immediately after air conditioning is turned off, refrigerant in sight glass stays clear Too much (1) Discharge refrigerant (2) Evacuate air and charge proper amount of purified refrigerant 6 When air conditioning is turned off, refrigerant foams and then stays clear Correct – *: Bubbles in the sight glass with ambient temperatures higher than usual can be considered normal if cooling is sufficient. 2001 PRIUS (RM778U) AC–4 AIR CONDITIONING – AIR CONDITIONING SYSTEM 2. INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET This is a method in which the trouble is located by using a manifold gauge set. Read the manifold gauge pressure when the these conditions are established. Test conditions:  Temperature at the air inlet with the switch set at RECIRC is 30 – 35 °C (86 – 95 °F)  Engine running at 1500 rpm  Blower speed control switch at ”HI” position  Temperature control dial on ”COOL” position HINT: It should be noted that the gauge indications may vary slightly due to ambient temperature conditions. (1) Normally functioning refrigeration system. Gauge reading: Low pressure side: 0.15 – 0.25 MPa (1.5 – 2.5 kgf/cm2) High pressure side: 1.37 – 1.57 MPa (14 – 16 kgf/cm2) I01386 2001 PRIUS (RM778U) AC–5 AIR CONDITIONING – (2) AIR CONDITIONING SYSTEM Moisture present in refrigeration system. Condition : Periodically cools and then fails to cool I01387 Symptom seen in refrigeration system Probable cause During operation, pressure on low pressure side sometimes become a vacuum and sometime normal Moisture entered in refrigeration system freezes at expansion valve orifice and temporarily stops cycle, by normal state is restored after a time when the ice melts Diagnosis (3)  Drier oversaturated state  Moisture in refrigeration system freezes at expansion valve orifice and blocks circulation of refrigerant Remedy (1) Replace condenser (2) Remove moisture in cycle through repeatedly evacuating air (3) Charge proper amount of new refrigerant Insufficient cooling Condition: Insufficient cooling I01388 Symptom seen in refrigeration system  Pressure low on both low and high pressure sides  Bubbles seen in sight glass continuously  Insufficient cooling performance 2001 PRIUS (RM778U) Probable cause Gas leakage at some place in refrigeration system Diagnosis  Insufficient refrigerant in system  Refrigerant leaking Remedy (1) Check for gas leakage with gas leak detector and repair if necessary (2) Charge proper amount of refrigerant (3) If indicated pressure value is near 0 when connected to gauge, create the vacuum after inspecting and repairing the location of the leak AC–6 AIR CONDITIONING (4) – AIR CONDITIONING SYSTEM Poor circulation of refrigerant Condition: Insufficient cooling I01389 Symptom seen in refrigeration system  Pressure low in both low and high pressure sides  Frost on tube from receiver to unit Probable cause Diagnosis Refrigerant flow obstructed by dirt in receiver (5) Receiver clogged Remedy Replace condenser Refrigerant does not circulate Condition: Does not cool (Cools from time to time in some cases) I01449 Symptom seen in refrigeration system  Vacuum indicated on low pressure side, very low pressure indicated on high pressure side  Frost or dew seen on piping before and after condenser/ drier or expansion valve 2001 PRIUS (RM778U) Probable cause Diagnosis  Refrigerant flow obstructed by moisture or dirt in refrigeration system Refrigerant does not circulate  Refrigerant flow obstructed by gas leakage from expansion valve Remedy (1) Check expansion valve (2) Clean out dirt in expansion valve by blowing with air (3) Replace condenser (4) Evacuate air and charge new refrigerant to proper amount (5) For gas leakage from expansion valve, replace expansion valve AC–7 AIR CONDITIONING – (6) AIR CONDITIONING SYSTEM Refrigerant overcharged or insufficient cooling of condenser Condition: Insufficient cooling I01390 Symptom seen in refrigeration system  Pressure too high on both low and high pressure sides  No air bubbles seen through the sight glass even when the engine rpm is lowered Probable cause Diagnosis Remedy  Unable to develop sufficient performance due to excessive refrigeration system  Insufficient cooling of condenser  Excessive refrigerant in cycle → refrigerant over charged  Condenser cooling → condenser fins clogged of condenser fan faulty (1) Clean condenser (2) Check condenser fan motor operation (3) If (1) and (2) are in normal state, check amount of refrigerant Charge proper amount of refrigerant (7) Air present in refrigeration system Condition: Insufficient cooling NOTE : These gauge indications are shown when the refrigeration system has been opened and the refrigerant charged without vacuum purging. I01392 Symptom seen in refrigeration system  Pressure too high on both low and high pressure sides  The low pressure piping hot to touch  Bubbles seen in sight glass 2001 PRIUS (RM778U) Probable cause Air entered in refrigeration system Diagnosis  Air present in refrigeration system  Insufficient vacuum purging Remedy (1) Check compressor oil to see if it is dirty or insufficient (2) Evacuate air and charge new refrigerant AC–8 AIR CONDITIONING (8) – AIR CONDITIONING SYSTEM Expansion valve improperly Condition: Insufficient cooling I01450 Symptom seen in refrigeration system  Pressure too high on both low and high pressure sides  Frost or large amount of dew on piping on low pressure side Probable cause Diagnosis  Excessive refrigerant in low pressure piping  Expansion valve opened too wide Trouble in expansion valve (9) Remedy Check expansion valve Replace if defective Defective compression compressor Condition : Does not cool I01393 Symptom seen in refrigeration system  Pressure too high on low and high pressure sides  Pressure too low on high pressure side 2001 PRIUS (RM778U) Probable cause Internal leak in compressor Diagnosis  Compression defective  Valve leaking or broken sliding parts Remedy Repair or replace compressor AC–9 AIR CONDITIONING – AIR CONDITIONING SYSTEM 3. (a) INSPECT FOR LEAKAGE OF REFRIGERANT Perform in these conditions:  Stop engine.  Secure good ventilation (If the gas leak detector may not react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas.)  Repeat the test 2 or 3 times.  Make sure that there is some refrigerant remaining in the refrigeration system. When compressor is OFF: approx. 392 – 588 kPa (4 – 6 kgf/ cm2, 57 – 85 psi) (b) Bring the gas leak detector close to the drain hose before performing the test. Drain Hose HINT:  N14519 2001 PRIUS (RM778U) After the blower motor has stopped, leave the cooling unit for more than 15 minutes.  Expose the gas leak detector sensor under the drain hose.  When bring the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to the volatile gases. If such reaction is unavoidable, the vehicle must be lifted up. (c) If gas leak is not detected on the drain hose, remove the blower resistor from the cooling unit. Then insert the gas leak detector sensor into the unit and perform the test. (d) Disconnect the connector and leave the pressure switch for approx. 20 minutes. Then bring the gas leak detector close to the pressure switch and perform the test. (e) Bring the gas leak detector close to the refrigerant lines and perform the test. AC–10 AIR CONDITIONING 4. (a) (b) – AIR CONDITIONING SYSTEM INSPECT IDLE–UP SPEED Activate inspection mode (See page IN–10). Inspect idle–up speed when the these conditions are established. Test conditions:  Idle speed set correctly.  Steering wheel straight ahead  Blower speed control dial at HI  A/C switch ON Magnetic clutch condition Idle speed Magnetic clutch not engaged 1,000 ±50 rpm Magnetic clutch engaged 1,000 ±50 rpm If idle speed is not as specified, check the engine ECU and throttle body. 2001 PRIUS (RM778U) AC–12 AIR CONDITIONING – AIR CONDITIONING SYSTEM AC20C–03 CHARGING 1. INSTALL CHARGING CYLINDER HINT: When handling the charging cylinder, always follow the directions given in the instruction manual. (a) Charge the proper amount of refrigerant into the charging cylinder. (b) Connect the center hose to the charging cylinder. CAUTION: Do not open both high and low hand valves of manifold gauge set. (c) Open the valve of charging cylinder. (d) Press the valve core on the side of manifold gauge and expel the air inside of the center hose. Push Air Low Pressure Service Valve High Pressure Service Valve Charging Cylinder N13793 2. (a) INSPECT REFRIGERATION SYSTEM FOR LEAKS Open the high pressure hand valve and charge refrigerant. (b) When the low pressure gauge indicates 98 kPa (1 kgf/cm2, 14 psi) close the high pressure hand valve. (c) Using a gas leak detector, check the system for leakage. If leak is found, repair the faulty component or connection. CAUTION: Use the refrigerant recovery/ recycling machine to recover the refrigerant whenever replacing parts. Gas Leak Detector N13792 2001 PRIUS (RM778U) AC–13 AIR CONDITIONING – AIR CONDITIONING SYSTEM 3. Low Pressure Service Valve High Pressure Service Valve N13790 CHARGE REFRIGERANT INTO REFRIGERANT SYSTEM If there is no leak after refrigerant leak check, charge the proper amount of refrigerant into refrigeration system. CAUTION:
Never run the engine when charging the system through the high pressure side.
Do not open the low pressure hand a valve when the system is being charged with liquid refrigerant. (a) Open the high pressure hand valve fully. (b) Charge specified amount of refrigerant, then close the high pressure hand valve. HINT: A fully charged system is indicated by the sight glass being free of any bubbles. (c) Charge partially refrigeration system with refrigerant. (1) Set vehicle in these conditions:
MAX. switch ON
Blower speed control set at ”HI”
Temperature control set at ”MAX. COOL”
Air inlet control set at ”RECIRC”
Running engine at 1,500 rpm
Fully open doors (2) Open the low pressure hand valve. CAUTION: Do not open the high pressure hand valve. (d) (e) Properly Charged Insufficiently Charged I17972 2001 PRIUS (RM778U) Charge refrigerant until bubbles disappear and check the pressure on the gauge through the sight glass. Replenishment to be 100 ± 50 g after bubbles disapper. AC–23 AIR CONDITIONING – AIR CONDITIONING UNIT AIR CONDITIONING UNIT AC37J–01 COMPONENTS Instrument Panel Outer Front Cowl Top Panel Defroster Duct Reinforcement Water Hose Clamp Suction Tube Liquid Tube A/C Unit Brace
O–Ring Clamp Air Inlet Duct Blower Unit Brake ECU Foot Air Duct ECM & EMPS ECU
Non–reusable part I17980 2001 PRIUS (RM778U) Author: Date: 1911 AC–24 AIR CONDITIONING – AIR CONDITIONING UNIT Expansion Valve Evaporator Tube & Accessory 3.5 (35, 30 in.·lbf)
O–Ring Plate Plate Thermistor Insulator Wire Harness Aspirator Hose Aspirator Clamp Eraporator Cover Air Mix Servomotor Air Outlet Servomotor Foot Air Duct A/C Unit Drain Hose PTC Heater Foot Air Duct Heater Radiator Rear Foot Duct Heater Pipe Cover N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part I18112 2001 PRIUS (RM778U) Author: Date: 1912 AC–25 AIR CONDITIONING – AIR CONDITIONING UNIT AC37K–01 REMOVAL 1. 2. REMOVE FRONT WIPER AND OUTER FRONT COWL TOP PANEL (See page BO–32) DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 500 ± 50 g (17.64 ± 1.76 oz.) 3. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all coolant. 4. (a) DISCONNECT LIQUID TUBE AND SUCTION HOSE Using SST, remove the 2 piping clamps. SST 09870–00015 (Suction tube) 09870–00025 (Liquid tube) I17981 (1) Insert SST to piping clamp. HINT: Confirm the direction of the piping clamp claw and SST using the illustration showing on the caution label. SST I03838 Push SST (2) Push down SST and release the clamp lock. NOTICE: Be careful not to deform the tubes, when pushing SST. (3) Pull SST slightly and push the release lever, then remove the piping clamp with SST. (4) Remove the piping clamp from SST. (b) Disconnect the both tubes. Pull SST Release Lever 2001 PRIUS (RM778U) I03839 AC–26 AIR CONDITIONING – AIR CONDITIONING UNIT NOTICE:
Do not use tools like screwdriver to remove the tube.
Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of reassembly, please refer to the following item. Lubricate 4 new O–rings with compressor oil and install them to the valve. Disconnect the tube using hand Screw Driver Tube I06919 5. (a) (b) DISCONNECT WATER HOSES FROM HEATER RADIATOR PIPES Using pliers, grip the claw of the hose clip and slide the hose clip along the hose. Disconnect the heater hoses. I17982 Hose Clip View A View A 20° Second Ridge Upper 20° Upper RH LH Lower Marking Lower HINT: At the time of installation, please refer to the following item. Push the water hose onto the heater radiator pipe as far as second ridge on the pipe and install the hose clip. 6. REMOVE INSTRUMENT PANEL AND REINFORCEMENT (See page BO–62) 7. REMOVE BLOWER UNIT (See page AC–32) I18108 8. (a) (b) REMOVE A/C UNIT Remove the 2 screws and defroster duct. Remove the foot air duct. (c) (d) Disconnect the connectors. Remove the 2 nuts and A/C unit. I17984 I17985 2001 PRIUS (RM778U) AC–40 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH AC35U–01 DISASSEMBLY 1. (a) REMOVE PRESSURE PLATE Using SST and a socket wrench, remove the shaft bolt. SST 07112–76050 Torque: 13.2 N·m (135 kgf·cm, 9 ft·lbf) (b) (d) Install SST to the pressure plate. SST 07112–66040 Using SST and a socket wrench, remove the pressure plate. SST 07112–76050, 07112–66040 Remove the shims from the shaft. 2. (a) REMOVE ROTOR Remove the snap ring. SST I11223 (c) SST I18010 I18012 NOTICE: At the time of reassembly, please refer to the following item. The snap ring should be installed so that its beveled side faces up. Snap Ring R–Shape Rotor Compressor N20013 (b) Using a plastic hammer, tap the rotor off the shaft. NOTICE: Be careful not to damage the pulley when tapping on the rotor. I18011 2001 PRIUS (RM778U) AC–41 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH 3. (a) (b) REMOVE STATOR Disconnect the connector from the stator. Remove the screw and stator lead wire. (c) Remove the snap ring. I18013 I18014 NOTICE: At the time of reassembly, please refer to the following item. The snap ring should be installed so that its beveled side faces up. R–Shape Snap Ring Startor Compressor N20012 (d) N18359 2001 PRIUS (RM778U) Remove the stator. AC–45 AIR CONDITIONING – RADIATOR AND CONDENSER MODULE AC36Q–01 COMPONENTS Water Hose Bracket Bracket Radiator Upper Support Radiator Upper Support 32 (330, 24)
O–Ring
O–Ring Suction Tube Radiator Hose Radiator Reservoir Hose Suction Hose 10 (100, 7) Radiator and Condenser Module
O–Ring Connector 5.4 (55, 48 in.·lbf) Condenser Fan
O–Ring Discharge Hose RH Engine Under Cover 22 (225, 16)
O–Ring
O–Ring LH Engine Under Cover Discharge Tube Liquid Tube 5.4 (55, 48 in.·lbf) Front Bumper Front Spoiler Cover N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part 2001 PRIUS (RM778U) I17953 AC–46 AIR CONDITIONING – RADIATOR AND CONDENSER MODULE Radiator & Condenser Module Drier Filter
O–Ring Cap 12.3 (125, 9) Bracket N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Compressor oil ND–OIL 8 or equivalent I18287 2001 PRIUS (RM778U) AC–47 AIR CONDITIONING – RADIATOR AND CONDENSER MODULE AC36R–01 REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 500 ± 50 g (17.64 ± 1.76 oz.) 2. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant. 3. REMOVE CONDENSER FAN ASSEMBLY (See Page AC–69) 4. REMOVE FRONT BUMPER (See Page BO–4) 5. REMOVE RADIATOR RESERVOIR HOSE 6. (a) I17955 DISCONNECT DISCHARGE AND LIQUID TUBE Remove the 2 bolts and disconnect discharge and liquid tube. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) NOTICE: Cap open the fittings immediately to keep moisture or dirt out of the system. HINT: At the time of installation, please refer to the following item. Lubricate 2 new O–rings with compressor oil and install them to the tubes. (b) Remove the bolt. (c) Disconnect the liquid tube and remove the bracket. 7. REMOVE RADIATOR UPPER SUPPORT Remove the 2 bolts and 2 radiator upper supports. I17954 2001 PRIUS (RM778U) AC–48 AIR CONDITIONING 8. (a) (b) (c) I17968 2001 PRIUS (RM778U) – RADIATOR AND CONDENSER MODULE REMOVE RADIATOR & CONDENSER MODULE Push the radiator & condenser module toward engine. Pull up the radiator until the lower radiator support is removed. Pull it downward to remove it. AC–65 AIR CONDITIONING – RELAY RELAY Heater Main Relay AC36O–01 Cooling Fan No. 1 Relay Magnetic Clutch Relay Cooling Fan No. 3 Relay Water Pump Relay INSPECTION 1. (a) REMOVE RELAY Remove the relay from the engine room J/B. (b) Remove the relay from the engine room R/B No. 3. 2. INSPECT HEATER MAIN RELAY CONTINUITY Cooling Fan No. 2 Relay I18027 Heater 1 Relay Heater 3 Relay Heater 2 Relay I18028 4 3 5 4 2 3 1 5 Condition Tester connection Specified condition Constant 3–5 2–4 Continuity Apply B+ between terminals 5 and 3. 1–2 Continuity If continuity is not as specified, replace the relay. 2 1 I18286 3. 3 5 2 INSPECT COOLING FAN NO. 2 RELAY CONTINUITY Condition Tester connection Specified condition Constant 1–2 3–4 Continuity Apply B+ between terminals 1 and 2. 3–5 Continuity If continuity is not as specified, replace the relay. 1 4 N23635 4. 2 1 3 5 3 1 2 INSPECT MAGNETIC CLUTCH, COOLING FAN NO. 1, 3, HEATER 1, 2, WATER PUMP RELAY CONTINUITY Condition Tester connection Specified condition Constant 1–2 Continuity Apply B+ between terminals 1 and 2. 3–5 Continuity If continuity is not as specified, replace the relay. 5 Z18060 2001 PRIUS (RM778U) Author: Date: 1953 AC–66 AIR CONDITIONING 5. 3 2 1 2 1 5 3 – RELAY INSPECT HEATER 3 RELAY CONTINUITY Condition Tester connection Specified condition Constant 1–2 Continuity Apply B+ between terminals 1 and 2. 3–5 Continuity If continuity is not as specified, replace the relay. 5 I07286 2001 PRIUS (RM778U) Author: Date: 1954 AC–69 AIR CONDITIONING – CONDENSER FAN AC36D–01 REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 500 ± 50 g (17.64 ± 1.76 oz.) 2. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all coolant. 3. (a) (b) REMOVE BRACKETS Remove the water hose from fan shroud. Remove the 5 bolts and 2 brackets. 4. (a) REMOVE SUCTION AND DISCHARGE HOSES Remove the 2 bolts and disconnect the both hoses. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) I17963 I17964 2001 PRIUS (RM778U) HINT: At the time of installation, please refer to the following item. Lubricate 2 new O–rings with compressor oil and install them to the tubes. (b) Loosen the 2 nuts and remove the both hoses. Torque: Suction hose 32 N·m (330 kgf·cm, 24 ft·lbf) Discharge hose 22 N·m (225 kgf·cm, 16 ft·lbf) HINT: At the time of installation, please refer to the following item. Lubricate 2 new O–rings with compressor oil and install them to the tubes. AC–70 AIR CONDITIONING 5. – CONDENSER FAN (b) DISCONNECT RADIATOR HOSES FROM RADIATOR AND CONDENSER MODULE Using pliers, grip the claw of the hose clip and slide the clip along the hose. Disconnect the radiator hoses. 6. (a) (b) REMOVE CONDENSER FAN WITH FAN SHROUD Disconnect the 2 connectors. Remove the 2 bolts. (c) Pull up the condenser fan with fan shroud until the it is removed from the radiator and condenser module. Pull it downward to remove it. (a) I17965 I17967 (d) I17956 2001 PRIUS (RM778U) AC–76 AIR CONDITIONING – HEATER CONTROL ASSEMBLY AC36J–01 DISASSEMBLY 1. (a) (b) REMOVE CONTROL KNOBS Pull out the 5 control knobs. Remove the 3 nuts. I17991 2. REMOVE MULTI DISPLAY & RADIO RECEIVER ASSEMBLY Remove the 4 screws and multi display & radio receiver assembly. I18015 3. (a) REMOVE A/C AMPLIFIER Remove the 12 screws and cover. (b) Unlock the connector lock and pull out the flat harness from center cluster module. I18034 I18035 4. REMOVE BULBS Using a screwdriver, turn the bulb to the left and pull out the bulb. : Bulb 2001 PRIUS (RM778U) I18036 AC–77 AIR CONDITIONING – HEATER CONTROL ASSEMBLY 5. REMOVE CLUSTER MODULE CIRCUIT Remove the 6 screws and center cluster module. I18037 2001 PRIUS (RM778U) AC–78 AIR CONDITIONING – HEATER CONTROL ASSEMBLY AC36K–01 INSPECTION 1. (a) INSPECT ILLUMINATION OPERATION Connect the positive (+) lead from the battery to terminal 5 and negative (–) lead to terminal 10, then check that the illumination lights up. If operation is not as specified, check the faulty bulb. 5 10 : Bulb I18038 (b) Apply the tester as shown in the illustration to the test for continuity. If continuity exists, replace the heater control. If no continuity exists, replace the bulb. I07872 7 1 I17978 2001 PRIUS (RM778U) 2. INSPECT INDICATOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and negative (–) lead to terminal 7, then check that the illumination light up. If operation is not as specified, proceed next inspection. AC–79 AIR CONDITIONING – HEATER CONTROL ASSEMBLY 3. INSPECT F/R INDICATOR OPERATION Connect the positive (+) lead from the two 1.5 V dry cell batteries to terminal 1 and negative (–) lead to terminal 3, then check that the F/R indicator lights up. If operation is as specified, replace the A/C amplifier. If operation is not as specified, replace the cluster module circuit. 3 2 Dry Cell Batteries 1 I18039 1 5 2 Dry Cell Batteries I18040 15 1 2 Dry Cell Batteries 14 8 5. INSPECT MAX. A/C INDICATOR OPERATION Connect the positive (+) lead from the two 1.5 V dry cell batteries to terminal 1 and negative (–) lead to terminal 15, then check that the MAX. A/C indicator lights up. If operation is as specified, replace the A/C amplifier. If operation is not as specified, replace the cluster module circuit. I18043 6. INSPECT SWITCH CONTINUITY Check the continuity between terminals while switch is pressed, as shown in the chart. 6 13 I18044 2001 PRIUS (RM778U) 4. INSPECT A/C INDICATOR OPERATION Connect the positive (+) lead from the two 1.5 V dry cell batteries to terminals 1 and negative (–) lead to terminal 5, then check that the A/C indicator lights up. If operation is as specified, replace the A/C amplifier. If operation is not as specified, replace the cluster module circuit. Switch Tester connection Specified condition F/R 6 – 13 Below 500 Ω A/C 8 – 13 Below 500 Ω MAX. A/C 13 – 14 Below 500 Ω If operation is not as specified, replace the cluster module circuit. AC–80 AIR CONDITIONING 7. (a) 13 9 (b) (c) 12 3 Dry Cell Batteries I18046 – HEATER CONTROL ASSEMBLY INSPECT MODE CONTROL DIAL OPERATION Check that the resistance between terminals 12 and 13 is approx. 3.0 kΩ. Connect the positive (+) lead from the three 1.5 V dry cell batteries to terminal 9 and negative (–) lead to terminal 13. Connect the positive (+) lead from the tester to terminal 12 and negative (–) lead to terminal 13, then check that the voltage at each dial position, as shown in the chart below. Dial position Specified condition FACE → B/L 0.7 V B/L → FOOT 2.0 V FOOT → F/D 3.2 V F/D → DEF 4.4 V If operation is not as specified, replace the cluster module circuit. 8. COOL WARM 13 9 11 3 Dry Cell Batteries I18047 INSPECT TEMPERATURE CONTROL DIAL OPERATION (a) Check that the resistance between terminals 11 and 13 is approx. 3.0 kΩ. (b) Connect the positive (+) lead from the three 1.5 V dry cell batteries to terminal 9 and negative (–) lead to terminal 13. (c) Connect the positive (+) lead from the tester to terminal 11 and negative (–) lead to terminal 13. (d) Gradually turn the dial from ”MAX. COOL” side to ”MAX. WARM” side and check that the voltage increase from 4.5 to 0.4 V. If operation is not as specified, replace the cluster module circuit. 9. M1 M2 (a) 9 (b) 13 3 Dry Cell Batteries 2001 PRIUS (RM778U) 10 I18045 INSPECT BLOWER SPEED CONTROL DIAL OPERATION Check that the resistance between terminals 10 and 13 is approx. 3.0 kΩ. Connect the positive (+) lead from the three 1.5 V dry cell batteries to terminal 9 and negative (–) lead to terminal 13. AC–81 AIR CONDITIONING (c) – HEATER CONTROL ASSEMBLY Connect the positive (+) lead from the tester to terminal 10 and negative (–) lead to terminal 13 then check that the voltage at each dial position, as shown in the chart below. Dial position Specified condition OFF → AUTO 1.45 V AUTO → LO 2.25 V LO → M1 3.05 V M1 → M2 3.85 V M2 → H1 4.65 V If operation is not as specified, replace the cluster module circuit. 2001 PRIUS (RM778U) DI–661 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI7NK–01 Cruise Control Switch Circuit CIRCUIT DESCRIPTION This circuit carries the SET/COAST, RESUME/ACCEL and CANCEL signal (each voltage) to the ECU. WIRING DIAGRAM Hybrid Vehicle Control ECU C14 Cruise Control SW (Comb. SW) W–B A J18 A J19 4 W–B ECC CANCEL SET/ COAST RES/ ACC CRUISE CCS 5 L J17 J/C 16 H14 CCS A IG I15478 2001 PRIUS (RM778U) DI–662 DIAGNOSTICS – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminals CCS of hybrid vehicle control ECU connector and body ground. PREPARATION: (a) Remove the hybrid vehicle control ECU with connector still connected. (b) Turn ignition switch ON. CHECK: Measure voltage between terminals CCS of hybrid vehicle control ECU connector and body ground, when each of the SET/ COAST, RESUME/ACCEL and CANCEL is turned ON. ON (+) (–) CCS Switch position Voltage (V) Neutral 10 –16 V RES/ACC 2.4 – 3.8 V SET/COAST 4.7 – 6.9 V CANCEL 6.9 – 9.8 V I19096 NG OK 2001 PRIUS (RM778U) Proceed to next circuit inspection shown in problem symptoms table (See page DI–648). DI–663 DIAGNOSTICS 2 – CRUISE CONTROL SYSTEM Check control switch continuity. PREPARATION: (a) Remove steering wheel center pad. (b) Disconnect the control switch connector. CHECK: Measure resistance between terminals 4 and 5 of control switch connector when control switch is operated. RES/ACC CANCEL SET/COAST 4 3 NG I05156 Switch position Resistance (Ω) Neutral ∞ (No continuity) RES/ACC 220 – 260 SET/COAST 600 – 660 CANCEL 1,500 – 1,600 Replace control switch. OK 3 Check main switch continuity. CRUISE MAIN Switch 4 Switch position Tester connection Specified condition OFF – No continuity Hold ON 4–5 Continuity 3 I05126 2001 PRIUS (RM778U) PREPARATION: (a) Remove steering wheel center pad. (See page SR–6) (b) Disconnect the control switch connector. CHECK: Check continuity between terminals 4 and 5 of control switch connector when main switch is held ON and OFF. OK: NG Replace control switch. DI–664 DIAGNOSTICS – CRUISE CONTROL SYSTEM OK 4 Check harness and connector between hybrid vehicle control ECU and cruise control switch, cruise control switch and body ground (See page IN–41). NG OK Check and replace hybrid vehicle control ECU (See page IN–41 ). 2001 PRIUS (RM778U) Repair or replace harness or connector. DI–679 DIAGNOSTICS – COMBINATION METER SYSTEM DI7XW–01 4. Fuel receiver gauge is inoperative or improper INSPECTION PROCEDURE 1 Fuel gauge diagnosis check. (See page DI–669) 2 Reset inclination sensor. (See page BE–47) 3 Fuel sender gauge check. (See page BE–42) NG Replace fuel tank. OK 4 Multiplex communication circuit check. (See page DI–750) CHECK: Check if the communication between the combination meter and the multiplex communication circuit is normal or not. No Yes 2001 PRIUS (RM778U) Multiplex communication circuit error. Wire harness faulty. DI–680 DIAGNOSTICS 5 – COMBINATION METER SYSTEM Check the body ECU. CHECK: With the fuel sender gauge connector connected, check if the voltage between each of terminal 1 (FV), 5 (FR) and 6 (FE) of the vehicle side wire harness and connector and the body ground is normal or not. Fuel Sender Gauge Connector Condition Terminal Ignition switch ON 1 (FV) – Body ground 4.5 – 5.5 V Ignition switch ON 5 (FR) – Body ground 0.5 – 5.5 V constant 6 (FE) – Body ground Continuity is always identified. I17867 No Yes Combination meter ECU faulty. 2001 PRIUS (RM778U) Specified value Body ECU faulty.