Toyota Prius 2010 Operating instructions

ILLUSTRATION

ON-VEHICLE INSPECTION
1. INSPECT THROTTLE BODY ASSEMBLY
(a) Check for throttle control motor operating sound.
(1) Turn the power switch on (IG).
(2) When depressing the accelerator pedal, check the operating sound of the motor. Make sure that no friction
noises are emitted from the motor. If any friction noise exists, replace the throttle body assembly.
(b) Set the vehicle to the inspection mode .
(c) Start the engine and check that the MIL is not illuminated. After the engine is warmed up, check that the idle
speed is within the specified range when the A/C is switched off.
Standard:
Condition
Engine Idle Speed
A/C switched off
950 to 1050 rpm
NOTICE:
x Be sure to perform this step with all accessories off.
x Make sure that park (P) is selected.

REMOVAL
1. REMOVE NO. 1 ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT (for Engine)
3. REMOVE NO. 2 CYLINDER HEAD COVER
4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
(a) Disconnect the mass air flow meter connector.
(b) Release the 2 clamps.
(c) Loosen the hose clamp and remove the air cleaner cap.
5. REMOVE INLET AIR CLEANER ASSEMBLY
(a) Separate the hose from the hose clamp.

(b) Separate the wire harness clamp from the inlet air cleaner assembly.
(c) Remove the 3 bolts and inlet air cleaner assembly.
6. REMOVE AIR CLEANER CASE
(a) Remove the air cleaner filter element.
(b) Separate the hose from the 3 hose clamps.
(c) Remove the 3 bolts and air cleaner case.
7. REMOVE AIR CLEANER HOSE ASSEMBLY
(a) Loosen the hose clamp and separate the ventilation hose.

(b) Unlock the hose clamp and remove the air cleaner hose assembly.
8. REMOVE THROTTLE BODY ASSEMBLY
(a) Disconnect the throttle body connector and the 2 water by
-
pass hoses.
(b) Remove the 2 bolts, 2 nuts and throttle body assembly.
(c) Remove the gasket from the intake manifold.

INSPECTION
1. INSPECT THROTTLE BODY ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Text in Illustration
*1
Component without harness connected
(Throttle Body)
Standard Resistance:
Tester Connection
Condition
Specified Condition
1 (M-) - 2 (M+)
20°C (68°F)
0.3 to 100 Ω
If the result is not as specified, replace the throttle body assembly.

INSTALLATION
1. INSTALL THROTTLE BODY ASSEMBLY
(a) Install a new gasket onto the intake manifold.
(b) Install the throttle body assembly with the 2 bolts and 2 nuts.
Torque:
10 N·m (102 kgf·cm, 7ft·lbf)
(c) Connect the 2 water by-pass hoses and throttle body connector.
2. INSTALL AIR CLEANER HOSE ASSEMBLY
(a) Install the air cleaner hose assembly and lock the hose clamp.
(b) Connect the ventilation hose.
3. INSTALL AIR CLEANER CASE
(a) Install the air cleaner case with the 3 bolts.
Torque: 7.0 N·m (71 kgf·cm, 62in·lbf)

(b) Install the hose to the 3 hose clamps.
(c) Install the air cleaner filter element.
4. INSTALL INLET AIR CLEANER ASSEMBLY
(a) Install the inlet air cleaner assembly with the 3 bolts.
Torque:
7.0 N·m (71 kgf·cm, 62in·lbf)
(b) Connect the wire harness clamp to the inlet air cleaner assembly.
(c) Install the hose to the hose clamp.
5. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
(a) Install the air cleaner cap sub
-
assembly with the 2 clamps.

(b) Tighten the hose clamp.
(c) Connect the mass air flow meter connector.
6. ADD ENGINE COOLANT (for Engine)
7. INSPECT FOR COOLANT LEAK (for Engine)
8. INSTALL NO. 2 CYLINDER HEAD COVER
9. INSTALL NO. 1 ENGINE UNDER COVER
10. PERFORM INITIALIZATION
NOTICE:
Be sure to perform this procedure after reassembling the throttle body assembly, removing and reinstalling any
throttle body component or replacing the ECM.
(a) Disconnect the cable from the negative (-) battery terminal. Wait at least 60 seconds and reconnect the cable.
(b) Connect the Techstream to the DLC3 and clear the DTCs .
(c) Set the vehicle to the inspection mode .
(d) Start the engine without operating the accelerator pedal and check that the MIL is not illuminated and that
the idle speed is within the specified range when the air conditioning is switched off after the engine is warmed
up.
Standard:
Condition
Engine Idle Speed
A/C switched off
950 to 1050 rpm
NOTICE:
x If the accelerator pedal is operated, perform the above steps again.
x Be sure to perform this step with all accessories off.
x Make sure that park (P) is selected.
(e) Perform a road test and confirm that there are no abnormalities.

Timothy Frank 2010 Toyota Prius
DTC CHECK / CLEAR
NOTICE:
When the diagnosis system is changed from normal mode to check mode or vice versa, all DTCs and freeze
frame data recorded in normal mode are cleared. Before changing modes, always check and make a note of
DTCs and freeze frame data.
HINT:
x DTCs which are stored in the ECM can be displayed on the Techstream. The Techstream can display the
current, pending and permanent DTCs.
x If a malfunction is detected during the current driving cycle, current and permanent DTCs are stored.
x Some DTCs are not stored if the ECM does not detect the same malfunction again during a second
consecutive driving cycle. However, such malfunctions, detected on only one occasion, are stored as
pending DTCs.
x Current and pending DTCs can be cleared by using the Techstream or by disconnecting the cable from
the negative battery terminal. However, permanent DTCs cannot be cleared using either of these two
methods.
x After clearing current DTCs using the Techstream (or by disconnecting the cable from the negative
battery terminal), permanent DTCs can be cleared when the system is determined to be normal for the
relevant DTCs and then the universal trip is performed. The driving pattern to obtain a normal judgment
is described under the "Confirmation Driving Pattern" for the respective DTC.
2 Trip Detection Examples
Pending
DTC
Store
condition
Malfunction detected
Clear
condition
System determined to be normal
or
DTCs cleared using Techstream
or
Cable disconnected from negative (-) battery terminal
Current
DTC
Store
condition
Malfunction detected (2nd trip)
Clear
condition
No malfunctions in 40 driving cycles
or
DTCs cleared using Techstream
or
Cable disconnected from negative (-) battery terminal
Permanent
Store
Malfunction detected (2nd trip)

Timothy Frank 2010 Toyota Prius
DTC
condition
Clear
condition
Power switch turned to on (IG) after normal judgment obtained in 3 consecutive
driving cycles
or
After DTCs cleared using Techstream or cable disconnected from negative (
-)
battery
terminal, normal judgment obtained and universal trip performed (not for misfire and
fuel system DTCs)
or
After DTCs cleared using Techstream or cable disconnected from negative (
-
) battery
terminal, malfunction not detected when universal trip driving performed (misfire
and fuel system DTCs)
MIL
ON
Malfunction detected (2nd trip)
OFF
Power switch turned to on (IG) after normal judgment obtained in 3 consecutive
driving cycles
or
DTCs cleared using Techstream
or
Cable disconnected from negative (-) battery terminal

Timothy Frank 2010 Toyota Prius
HINT:
x Obtaining a normal judgment and performing a universal trip driving pattern can be done in the same
driving cycle or in different driving cycles.
x It is unnecessary to obtain a normal judgment if the DTCs are misfire or fuel system DTCs.
1. CHECK DTC
(a) Connect the Techstream to the DLC3.
(b) Turn the power switch on (IG).
(c) Turn the Techstream on.
(d) Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.
(e) Check the DTC(s) and freeze frame data, and then write them down.
(f) Check the details of the DTC(s) .
2. CLEAR DTC (Pending and Current DTC)

Timothy Frank 2010 Toyota Prius
(a) Connect the Techstream to the DLC3.
(b) Turn the power switch on (IG).
(c) Turn the Techstream on.
(d) Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.
(e) Clear the DTCs.
3. CLEAR DTC (Pending and Current DTC without using Techstream)
(a) Perform either of the following operations:
(1) Disconnect the cable from the negative (-) battery terminal for more than 1 minute.
(2) Remove the EFI MAIN and ETCS fuses from the engine room relay block located inside the engine
compartment for more than 1 minute.
4. CLEAR PERMANENT DTC
HINT:
Even if the following procedure is not performed, permanent DTCs are cleared by obtaining a normal judgment
during 3 consecutive driving cycles.
(a) Connect the Techstream to the DLC3.
(b) Turn the power switch on (IG).

Timothy Frank 2010 Toyota Prius
(c) Turn the Techstream on.
(d) Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.
(e) Check if permanent DTCs are stored.
HINT:
If permanent DTCs are not output, it is not necessary to continue this procedure.
(f) Clear DTCs.
(g) Perform the respective confirmation driving patterns in order to obtain a normal judgment for the output
DTCs.
HINT:
x Confirmation driving patterns do not need to be performed for misfire and fuel system DTCs.
x For the confirmation driving pattern, refer to the procedures for the relevant DTC .
(h) Perform the universal trip.
HINT:
The driving pattern to obtain a normal judgment and the universal trip driving can be performed consecutively
in the same driving cycle.
1. Put the engine in inspection mode .
2. Idle the engine for 30 seconds or more.
3. Drive the vehicle at 25 mph (40 km/h) or more for a total of 5 minutes or more.
HINT:
It is possible to complete the drive pattern even if the vehicle decelerates to less than 25 mph (40 km/h)
during the driving cycle provided that the vehicle is driven at 25 mph (40 km/h) or more for a total of 5
minutes.
4. Allow 10 minutes or more to elapse from the time the engine is started.
(i) Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.
(j) Check that the permanent DTCs have been cleared.
HINT:
The permanent DTCs are cleared when the universal trip is completed.

Timothy Frank 2010 Toyota Prius
REMOVAL
1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a) Remove the engine assembly with transaxle .
2. INSTALL ENGINE ON ENGINE STAND
3. REMOVE ENGINE HANGERS
4. REMOVE THROTTLE BODY ASSEMBLY
5. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE
6. REMOVE EGR PIPE ASSEMBLY
7. REMOVE EGR VALVE ASSEMBLY
8. REMOVE EGR WITH COOLER PIPE SUB-ASSEMBLY
9. REMOVE INTAKE MANIFOLD
10. REMOVE FUEL VAPOR FEED PIPE
11. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
12. REMOVE NO. 1 DELIVERY PIPE SPACER
13. REMOVE FUEL INJECTOR ASSEMBLY
14. REMOVE IGNITION COIL ASSEMBLY
15. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
16. REMOVE CYLINDER HEAD COVER GASKET
17. REMOVE SPARK PLUG TUBE GASKET
18. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley until its notch and timing mark "0" of the
timing chain cover are aligned.
Text in Illustration
*1
Timing Mark

Timothy Frank 2010 Toyota Prius
*2
Timing Notch
(b) Check that timing marks on both the camshaft timing sprocket and camshaft timing gear are facing upward
as shown in the illustration.
If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.
19. REMOVE CRANKSHAFT PULLEY
20. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY
(a) Remove the 2 nuts, bracket, chain tensioner and gasket.
NOTICE:
Do not turn the crankshaft without the No. 1 chain tensioner installed.
21. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
22. REMOVE TIMING CHAIN COVER OIL SEAL
23. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the chain tensioner slipper from the cylinder block.

Timothy Frank 2010 Toyota Prius
24. REMOVE NO. 1 CHAIN VIBRATION DAMPER
(a) Remove the 2 bolts and chain vibration damper.
25. REMOVE NO. 2 CHAIN VIBRATION DAMPER
(a) Remove the 2 bolts and No. 2 chain vibration damper.
26. REMOVE CHAIN SUB-ASSEMBLY
(a) Hold the hexagonal portion of the camshaft with a wrench and turn the
camshaft timing gear counterclockwise to loosen the chain between the
camshaft timing gears.

Timothy Frank 2010 Toyota Prius
(b) With the chain loosened, release the chain from the camshaft timing gear and place it on the camshaft timing
gear.
HINT:
Be sure to release the chain from the sprocket completely.
(c) Turn the camshaft clockwise to return it to the original position and remove the chain.
27. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
(a) Inspect the lock of the camshaft timing gear.
(b) After cleaning and degreasing the VVT oil hole on the intake side of
the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive
tape or equivalent as shown in the illustration to prevent air from leaking.
Text in Illustration
*1
Adhesive Tape
*a
Adhesive Tape Sealing Area
*b
Prick a Hole
NOTICE:
Be
sure to cover the oil hole completely because air leaks due to
insufficient sealing will prevent the lock pin from being released.
(c) Prick a hole in the tape covering the oil hole as shown in the illustration. (Procedure A)

Timothy Frank 2010 Toyota Prius
(d) Apply approximately 150 kPa (1.5 kgf/cm2, 22 psi) of air pressure to
the hole pricked in procedure A to release the lock pin.
x If air leaks out, reattach the adhesive tape.
x Cover the oil hole with a piece of cloth
when applying air pressure
to prevent oil from spraying.
(e) Forcibly turn the camshaft timing gear in the advance direction (counterclockwise).
HINT:
Depending on the air pressure applied, the camshaft timing gear may turn in the advance direction without
assistance.
(f) Turn the camshaft timing gear within its movable range (26.5 to 28.5°)
2 or 3 times without turning it to the most retarded position. Make sure
that the camshaft timing gear turns smoothly.
(g) Remove the adhesive tape from the No. 1 camshaft bearing cap.
28. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
(a) Remove the flange bolt while holding the hexagonal portion of the camshaft with a wrench, and then remove
the camshaft timing gear.
Text in Illustration
*1
Flange Bolt
*a
Do not remove