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
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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.
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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)
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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
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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
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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
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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).
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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)
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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
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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.
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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.
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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
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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
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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
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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
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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
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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 (Busline) 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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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.