Toyota Prius HSD 2004 User manual

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

Illustration:
what to do and where
Component part No.
Detailed text: how to perform task
Task heading: what you will be doing
Set part No.
INSTALL FRONT AXLE HUB BEARING
<FRONT AXLE HUB BEARING OUTER LH>
The ”< >” marks highlight the part’s name in the Parts Catalog
D31332
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2004 Prius – Preliminary Release (RM1075U)
(c) Torque specifications, grease application areas, and non–reusable parts are emphasized in the proce-
dures.
NOTICE:
There are cases where such information can only be explained by using an illustration. In these
cases, all the information such as torque, oil, etc. are described in the illustration.
(d) The installation procedures are the removal procedures in reverse order. However, only installation
procedures requiring additional information are included.
(e) Only items with key points are described in the text. What to do and other details are placed in illustra-
tions next to the text. Both the text and illustrations are accompanied by standard values and notices.
(f) Illustrations of similar vehicle models are sometimes used. In those cases, specific details may be dif-
ferent from the actual vehicle.
(g) Procedures are presented in a step–by–step format:
(1) The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The explanation text tells how to perform the task. It also has information such as specifications
and warnings.
Example:
HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
headings are easy to read and the text below the task heading provides detailed information. Important spec-
ifications and warnings are always written in bold type.
5. SERVICE SPECIFICATIONS
(a) SPECIFICATIONS are presented in bold–faced text throughout the manual. The specifications are
also found in the Service Specifications section for quick reference.
6. TERMS DEFINITION
CAUTION Possibilityof injury to you or other people.
NOTICE Possibility of damage to the components being repaired.
HINT Provides additional information to help you perform repairs.

–INTRODUCTION 2004 Prius – Preliminary Release (RM1075U) 01–3
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2004 Prius – Preliminary Release (RM1075U)
7. SI UNIT
(a) The units used in this manual comply with the SI UNIT (International System of Units) standard. Units
from the metric system and the English system are also provided.
Example:
Torque: 30 N⋅m (310 kgf⋅cm, 22 ft⋅lbf)

010RY–01
B76081
A
B
B76080
B
A
01–4 –INTRODUCTION 2004 Prius – Preliminary Release (RM1075U)
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2004 Prius – Preliminary Release (RM1075U)
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION AND SERIAL NUMBERS
1. VEHICLE IDENTIFICATION NUMBER
(a) The vehicle identification number is stamped on the ve-
hicle identification number plate and certification label, as
shown in the illustration.
A: Vehicle Identification Number Plate
B: Certification Label
2. ENGINE SERIAL NUMBER AND MOTOR SERIAL
NUMBER
(a) The engine serial number is stamped on the engine block,
as shown in the illustration.
A: Engine Serial Number
(b) The motor serial number is stamped on the motor as
shown in the illustration.
B: Motor Serial Number

010RZ–01
B73283
1
2
3
4
5
6
–INTRODUCTION 2004 Prius – Preliminary Release (RM1075U) 01–5
5Author: Date:
2004 Prius – Preliminary Release (RM1075U)
REPAIR INSTRUCTION
PRECAUTION
1. BASIC REPAIR HINT
(a) HINTS ON OPERATIONS
1 Looks Always wear a clean uniform.
A hat and safety shoes must be worn.
2Vehicle protection Prepare a grille cover, fender cover, seat cover and floor mat before starting the repairs.
3Safe operation
When working with 2 or more persons, be sure to check safety for one another.
When working with the engine running, make sure to provide ventilation for exhaust fumes in the
workshop.
If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety
equipment and take extra care not to injure yourself or others.
When jacking up the vehicle, be sure to support the specified location with a safety stand.
When lifting up the vehicle, use appropriate safety equipment.
4Preparation of tools and
measuring gauge Before starting operation, prepare a tool stand, SST, gauge, oil, shop rag and parts for replacement.
5Removal and installation, disassembly and assem-
bly operations
Diagnose with a thorough understanding of proper procedures and of the reported problem.
Before removing the parts, check the general condition of the assembly and for deformation and damage.
When the assembly is complicated, take notes. For example, note the total number of electrical connections,
bolts, or hoses removed. Add matchmarks to insure re–assembly of components in the original positions.
Temporarily mark hoses and their fittings, if needed.
Clean and wash the removed parts if necessary and assemble them after a thorough check.
6Removed parts
Place the removed parts in a separate box to avoid mixing them up with the new parts or contaminating the
new parts.
For non–reusable parts such as a gasket, O–ring, and self–locking nut, replace them with new ones following
the instructions in this manual.
Retain the removed parts for customer inspection, if requested.

Z11554
Seal Lock Adhesive
BE1367
Medium Current Fuse and High Current
Fuse Equal Amperage Rating
D27353D27353
V35002
Illustration Symbol Part Name Abbreviation
FUSE
MEDIUM CURRENT FUSE
HIGH CURRENT FUSE
FUSE
M–FUSE
H–FUSE
01–6 –INTRODUCTION 2004 Prius – Preliminary Release (RM1075U)
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2004 Prius – Preliminary Release (RM1075U)
(b) JACKING UP AND SUPPORTING VEHICLE
(1) Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the
vehicle at the proper locations (see page 01–34).
(c) PRECOATED PARTS
(1) Precoated parts are bolts and nuts that are coated
with a seal lock adhesive at the factory.
(2) If a precoated part is retightened, loosened or
moved in anyway, it must be recoated with the spe-
cified adhesive.
(3) When reusing precoated parts, clean off the old
adhesive and dry the part with compressed air.
Then apply new seal lock adhesive appropriate to
the bolts and nuts.
NOTICE:
Perform the torque with the lower limit value of the torque
tolerance.
(4) Some seal lock agents harden slowly. You may
have to wait for the seal lock agent to harden.
(d) GASKETS
(1) When necessary, use a sealer on gaskets to prevent leaks.
(e) BOLTS, NUTS AND SCREWS
(1) Carefully follow all the specifications for tightening torques. Always use a torque wrench.
(f) FUSES
(1) When replacing fuses, be sure that the new fuse
has the correct amperage rating. DO NOT exceed
the rating or use one with a lower rating.

D25786
Shape (Example) Removal/Installation
Clip Remover
Pliers
Screwdriver
Scraper
Protective Tape
Clip
Protective Tape
Remove clips from front or rear using clip remover
or pliers.
Remove fasteners with a clip remover or screwdriver.
Remove clips with a wide scraper to prevent
panel damage.
–INTRODUCTION 2004 Prius – Preliminary Release (RM1075U) 01–7
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2004 Prius – Preliminary Release (RM1075U)
(g) CLIPS
(1) The removal and installation methods of typical clips used in body parts are shown in the table
below.
HINT:
If clips are damaged during a procedure, always replace the damaged clip with a new clip.

V35006
Shape (Example) Removal/Installation
Removal Installation
Removal Installation
Removal Installation
Screwdriver
Screwdriver
Screwdriver
Clip Remover
Clip Remover
Clip Remover
Push
Push
Push
Small Clip Remover
Remove rivet by pushing the center pin through and prying
out the rivet shell.
Remove rivet by unscrewing the center pin and prying out
the rivet shell.
Remove rivet by prying out the pin and then prying out the
rivet shell.
01–8 –INTRODUCTION 2004 Prius – Preliminary Release (RM1075U)
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2004 Prius – Preliminary Release (RM1075U)

D31750
INCORRECT CORRECT
D25064
L1 L2L1 L2L1 L2L1 L2
D02612
L2L1 L2L1 L2L1 L2L1
D01201
–INTRODUCTION 2004 Prius – Preliminary Release (RM1075U) 01–9
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2004 Prius – Preliminary Release (RM1075U)
(h) REMOVAL AND INSTALLATION OF VACUUM HOSES
(1) To disconnect vacuum hoses, pull and twist from
the end of the hose. Do not pull from the middle of
the hose as this may cause damage.
(2) When disconnecting vacuum hoses, use tags to
identify where they should be reconnected.
(3) After completing the job, double check that the vac-
uum hoses are properly connected. The label under
the hood shows the proper layout.
(4) When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step–down
adapter for adjustment. Once a hose has been
stretched, it may leak air.
(i) TORQUE WHEN USING TORQUE WRENCH WITH EX-
TENSION TOOL
(1) If SST or an extension tool is combined with the
torque wrench to extend its length, do not tighten
the torque wrench to the specified torque values in
this manual. The resulting torque will be excessive.
(2) Use the formula below to calculate special torque
values for situations where SST or an extension tool
is combined with the torque wrench.
(3) Formula: T’ = T x L2/(L1 + L2)
T’ Readingof torque wrench {N⋅m(kgf⋅cm, ft⋅lbf)}
TTorque {N⋅m(kgf⋅cm, ft⋅lbf)}
L1 Length of SST or extension tool (cm)
L2 Length of torque wrench (cm)

A83545
B76060
DO NOT WEAR
D32047
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2004 Prius – Preliminary Release (RM1075U)
2. PRECAUTIONS FOR HIGH–VOLTAGE CIRCUIT IN-
SPECTION AND SERVICE
(a) Engineer must undergo special training to be able to per-
form high–voltage system inspection and servicing.
(b) All high–voltage wire harness connectors are colored
orange. The HV battery and other high–voltage compo-
nents have ”High Voltage” caution labels. Do not care-
lessly touch these wires and components.
(c) Before inspecting or servicing the high–voltage system,
be sure to follow safety measures, such as wearing insu-
lated 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.
(d) After removing the service plug, wait 5 minutes before
touching any of the high–voltage connectors and termi-
nals.
HINT:
5 minutes are required to discharge the high–voltage condens-
er inside the inverter.
(e) Be sure to install the service plug before starting the hy-
brid system. Starting the hybrid system with the service
plug removed may damage the vehicle.
(f) Before wearing insulated gloves, make sure that they are
not cracked, ruptured, torn, or damaged in any way. Do
not wear wet insulated gloves.
(g) When servicing the vehicle, do not carry metal objects like
mechanical pencils or scales that can be dropped acci-
dentally and cause a short circuit.
(h) Before touching a bare high–voltage terminal, wear insu-
lated gloves and use an electrical tester to ensure that the
terminal is not charged with electricity (approximately 0
V).
(i) After disconnecting or exposing a high–voltage connec-
tor or terminal, insulate it immediately using insulation
tape.
(j) The screw of a high–voltage terminal should be tightened
firmly to the specified torque. Both insufficient and exces-
sive torque can cause failure.
(k) Use the ”CAUTION: HIGH VOLTAGE. DO NOT TOUCH
DURING OPERATION” sign to notify other engineers that
a high–voltage system is being inspected and/or re-
paired.
(l) Do not place the battery upside down while removing and
installing it.

–INTRODUCTION 2004 Prius – Preliminary Release (RM1075U) 01–11
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2004 Prius – Preliminary Release (RM1075U)
(m) After servicing the high–voltage system and before rein-
stalling the service plug, check again that you have not
left a part or tool inside, that the high–voltage terminal
screws are firmly tightened, and that the connectors are
correctly connected.

CAUTION:
HIGH VOLTAGE. DO
NOT TOUCH DURING
OPERATION.
CAUTION:
HIGH VOLTAGE. DO
NOT TOUCH DURING
OPERATION.
Person in charge:
Person in charge:
Copy this page and put it after folding on the roof of the vehicle in service.B75514
01–12 –INTRODUCTION 2004 Prius – Preliminary Release (RM1075U)
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2004 Prius – Preliminary Release (RM1075U)

B75513
D31846
Inverter
Relay Block
B75501
–INTRODUCTION 2004 Prius – Preliminary Release (RM1075U) 01–13
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2004 Prius – Preliminary Release (RM1075U)
3. PRECAUTIONS TO BE OBSERVED WHEN INSPECT-
ING OR SERVICING ENGINE COMPARTMENT
The PRIUS automatically turns the engine ON and OFF when
the READY light on the instrument panel is ON. To avoid injury,
remove the key from the key slot before inspecting or servicing
the engine compartment.
4. ACTIONS TO BE TAKEN WHEN BATTERIES ARE DE-
PLETED
(a) Perform this procedure when the auxiliary battery is fully
depleted.
HINT:
The following problems indicate that the auxiliary battery is de-
pleted:
No display appears on the instrument panel when the
power switch’s power mode is set to ON (IG).
The hybrid system does not start.
The headlights are dim.
The sound from the horn is weak.
NOTICE:
Never use a quick charger.
(1) Push the ”P” position switch, and engage the park-
ing brake.
(2) Remove the key from the key slot.
(3) 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.
(4) 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.
(5) Depress the brake pedal and push the power switch
to start the hybrid system.
If the hybrid system fails to start and the master lamp turns ON,
the HV battery may be depleted.
(6) Disconnect the booster cable in the reverse order of
the connection procedure.
NOTICE:
If the auxiliary battery needs to be replaced, replace it only
with a 12 V battery specially designed for use with the
PRIUS.
(b) Perform this procedure when the HV battery is depleted.
NOTICE:
Leaving the vehicle untouched for 2 to 3 months may de-
plete the HV battery. If the battery is fully depleted, replace
the HV battery.

B76088
Multi Information Display:
HV System Warning
01–14 –INTRODUCTION 2004 Prius – Preliminary Release (RM1075U)
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5. INSPECTION MODE
HINT:
The PRIUS’ engine automatically stops if the vehicle is stopped, the engine is warmed up, the battery
is well charged, and A/C compressor operation is not being used. Activate inspection mode when con-
tinuous operation of the engine is required.
The PRIUS has a motor TRAC function. When the wheel speed of the front wheels exceeds that of
rear wheels, the wheel speed of the front wheels is restrained. It is necessary to activate inspection
mode and deactivate the motor TRAC function when turning only the front wheels using a speedome-
ter tester.
(a) Vehicle conditions
(1) Before activating inspection mode, turn the air conditioning off, start the engine with the selector
lever in the P position, and check that the engine stops within several seconds after starting (en-
gine warm up check).
(2) Activate inspection mode and inspect the vehicle. The shift position for each test is as follows:
Test item Shift position Inspection mode
1. Vehicle straight travelling test
(side slip inspection) DON or OFF
2. Breaking force test NON or OFF
3. Speed meter test D ON
4. Exhaust gas test (idling) P ON
5. Headlight test PON or OFF
(3) Reset inspection mode immediately after completion of inspection.
NOTICE:
Driving the vehicle without resetting inspection mode may damage the transaxle.
(b) Special notes for speedometer test
NOTICE:
Do not use the speedmeter tester to perform rapid starting or quick accleration/deceleration without
first setting the proper load on the vehicle. Failing to set the load may damage the transaxle.
(1) Depress the accelerator pedal slowly and gradually accelerate the vehicle. Make a measure-
ment.
(2) After the measurement, use the brake to gradually decelerate the vehicle.
(c) Special note for using the chassis dynamometer
Always set an appropriate load before starting the test.
(d) Activating of inspection mode (Using the hand–held tes-
ter)
(1) Connect the hand–held tester to the DLC3.
(2) Push the power switch twice without depressing the
brake pedal and change the power mode to ON
(IG).
(3) Turn the hand–held tester ON.
(4) On the hand–held tester, select the item: DIAGNO-
SIS / ENHANCED OBD II / HV ECU / ACTIVE TEST
/ INSPECTION MODE / ON.

A82837
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2004 Prius – Preliminary Release (RM1075U)
(5) Activate inspection mode. Check that the HV sys-
tem warning on the multi–information display starts
blinking and master warning lamp on the combina-
tion meter is illuminated.
(6) Depress and hold the brake pedal, and then push
the power switch. The vehicle’s engine should run
continuously without stopping.
(e) Deactivating inspection mode
(1) Change the power switch’s power mode to OFF. In-
spection mode and the main system (HV system)
are turned off simultaneously.
NOTICE:
The idle speed in inspection mode is approximately
1,000 rpm. The number of revolutions will increase to:
1) 1,500 rpm if the accelerator pedal is less than 60 %
depressed, and 2) 2,500 rpm if the pedal is more than
60% depressed.
If a diagnosis code is recorded when entering inspec-
tion mode, the master lamp and the error warning
lamp on the multi–center display are illuminated.
When the master warning light is illuminated during
operation in inspection mode, deactivate inspection
mode and inspect the diagnosed area.
Traveling on a road without resetting inspection
mode may damage the transaxle.
HINT:
Depress and hold the brake pedal, and then push the power switch. The vehicle’s engine should run continu-
ously without stopping.
6. ACTIONS TO BE TAKEN FOR VEHICLE DAMAGED BY IMPACT
(a) Items to be prepared or operation at the site of the accident
Protective clothing (insulated gloves, rubber gloves, goggles, and safety shoes)
Saturated boric acid solution 20 L (obtain 800 g of boric acid powder, put it into a container, and
dissolve it in water)
Red litmus paper
ABC fire extinguisher (effective against both oil flames and electrical flames)
Shop rags (for wiping off the electrolyte)
Vinyl tape (for insulating cable)
Electrical tester
(b) 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 the cable must be touched or
if accidental contact is unavoidable, follow these instructions: 1) wear insulated or rubber gloves
and goggles, 2) measure the voltage between the cable and the body ground using an electrical
tester, and 3) insulate the cable using vinyl tape.
(3) If the vehicle catches on fire, use an ABC fire extinguisher to extinguish the fire. Trying to extin-
guish a fire using only a small amount of water can be more dangerous than effective. Use a sub-
stantial amount of water or wait for firefighters.

B76085
High–voltage Part and Wiring
Inverter and Converter
HV Battery
Power Cable
Hybrid Transaxle
A/C Compressor
01–16 –INTRODUCTION 2004 Prius – Preliminary Release (RM1075U)
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2004 Prius – Preliminary Release (RM1075U)
(4) Visually check the HV battery and immediate area for any electrolyte leakage. Do not touch any
leaked liquid because it could be highly alkaline electrolyte. Wear rubber gloves and goggles,
and then apply red litmus paper to the leak. If the paper turns blue, the liquid must be neutralized
before wiping. Neutralize the liquid using the following procedures:
1) apply saturated boric acid solution to the liquid, and 2) reapply red litmus paper and make sure
it does not turn blue. Repeat steps 1 and 2 above until the paper does not turn blue. Then, wipe
the neutralized liquid with a shop rag.
(5) If damage to any of the high–voltage components and cables is suspected, cut the high–voltage
circuit using the procedure on the following pages.
Push the ”P” position switch and engage the park-
ing brake.
Remove the key from the key slot. Then disconnect
the negative (–) terminal of the auxiliary battery.

B75497
Service Plug
B74192
B74191 B76062
Engine Room J/B
Power Integration
HV Fuse
B75503
–INTRODUCTION 2004 Prius – Preliminary Release (RM1075U) 01–17
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2004 Prius – Preliminary Release (RM1075U)
Remove the service plug while wearing insulated
gloves.
Do not turn the power switch on while removing the
service plug.
If the service plug cannot be removed due to dam-
age to the rear portion of the vehicle, remove the HV
fuse or power integration (IGCT Relay) instead.
(c) Moving the damaged vehicle
HINT:
If any of the following applies, tow the vehicle away using a tow
truck.
One or more of the high–voltage components and cables
are damaged.
The driving, traction, or fuel system is damaged.
The READY lamp is not illuminated when you turn.
NOTICE:
Before towing the vehicle away using a tow truck, dis-
connect the cable from the negative (–) terminal of the
auxiliary battery and remove the service plug.
Only if none of the above applies and there are no
problems that might affect driving, drive the vehicle
away from the place of accident to a safe, nearby
place.
Perform the procedure below if the READY lamp turns
off, or there are abnormal noises, unusual smells, or
strong vibrations while driving:
(1) Park the vehicle in a safe place.
(2) Push the ”P” position switch and engage the park-
ing brake.
(3) Disconnect the power cable from the negative (–)
terminal of the auxiliary battery.
(4) Remove the service plug while wearing insulated
gloves.

01–18 –INTRODUCTION 2004 Prius – Preliminary Release (RM1075U)
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(d) Actions required after moving the damaged vehicle
If you see any liquid on the road surface, it could be highly
alkaline electrolyte leakage.
Wear rubber gloves and goggles, and apply red litmus pa-
per to the leak. If the paper turns blue, the liquid must be
neutralized before wiping. Neutralize the liquid using the
following procedures: 1) apply saturated boric acid solu-
tion to the liquid, and 2) red litmus paper and make sure
it does not turn blue. Repeat steps 1 and 2 above until the
paper does not turn blue. Then wipe the neutralized liquid
with a shop rag.
(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 (obtain 800 g of
boric acid powder, put it into a container, and dis-
solve it in water)
Red litmus paper
Shop rags (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 safe-
ty shoes.
(2) Do not touch a bare cable that could be a high volt-
age cable. If the cable must be touched or if acci-
dental contact is unavailable, follow these instruc-
tions: 1) wear insulated or rubber gloves and
goggles, 2) measure the voltage between the cable
and the body ground using an electrical tester, and
3) insulate the cable using vinyl tape.
(3) Check the HV battery and immediate area for any
electrolyte leakage. Do not touch any leaked liquid
because it could be highly alkaline electrolyte. Wear
rubber gloves and goggles, and then apply red lit-
mus paper to the leak. If the paper turns blue, the
liquid must be neutralized before wiping. Neutralize
the liquid using the following procedures:
1) apply saturated boric acid solution to the liquid,
and 2) reapply red litmus paper and make sure it
does not turn blue. Repeat steps 1 and 2 above until
the paper does not turn blue, Then wipe the neutral-
ized liquid with a shop rag.
(4) If the electrolyte adheres to your skin, wash the skin
immediately using saturated boric acid solution or
a large amount of water. If the electrolyte adheres
to an article of clothing, take it off immediately.

B76063
–INTRODUCTION 2004 Prius – Preliminary Release (RM1075U) 01–19
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2004 Prius – Preliminary Release (RM1075U)
(5) If the electrolyte comes in contact with your eyes,
call out loudly for help. Do not rub your eyes. Wash
them with a large amount of water and seek medical
care immediately.
(6) If damage to any of the high–voltage components
and cables is suspected, cut the high–voltage cir-
cuit using the procedure below.
Push the ”P” position switch and engage the
parking brake.
Remove the key from the key slot. Then dis-
connect the power 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, re-
move 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 to the location specified by the
manufacturer. The same applies to any damaged HV bat-
tery.
(h) After removing the battery, keep it away from water.Water
may heat the battery, which results in fire.
(i) 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.
(j) Towing with 4 wheels on the ground
NOTICE:
If the damaged vehicle needs to be towed using a
rope, do not exceed 30 km/h and tow only for very
short distances. Foe example, towing from the acci-
dent site to a nearby tow truck is permissible.
Change the power switch’s power mode to ON (IG)
and shift the selector lever to the N position.
If any abnormality is present in the damaged vehicle
during towing, stop towing immediately.
(k) Towing eyelet
(1) Install the hook.
(2) Hook a rope on to the illustrated area for towing.

01–20 –INTRODUCTION 2004 Prius – Preliminary Release (RM1075U)
20Author: Date:
2004 Prius – Preliminary Release (RM1075U)
7. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER
HINT:
The PRIUS is equipped with a Supplemental Restraint System (SRS) and seat belt pretensioner.
Failure to carry out the service operations in the correct sequence could cause the SRS to unexpectedly
deploy during servicing and lead to serious injury.
Furthermore, if a mistake is made when servicing the SRS, it is possible that the SRS may fail to operate
properly. Before servicing (including removal or installation of parts, inspection or replacement), be sure to
read the following section carefully.
(a) GENERAL NOTICE
(1) As the malfunction symptoms of the SRS are difficult to confirm the Diagnostic Trouble Codes
(DTCs) become the most important source of information when troubleshooting. When trouble-
shooting the SRS, always check the DTCs before disconnecting the battery (see page 05–1402).
(2) Work must be started at least 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. If work is started within 90 seconds after
turning the ignition switch to lock and disconnecting the negative (–) terminal cable from the bat-
tery, the SRS may deploy).
When the negative (–) terminal cable is disconnected from the battery, clock and audio system
memory is erased. Before starting work, make a note of the settings of each memory system.
When work is finished, reset the clock and audio systems as before.
CAUTION:
Never use the back–up power source (battery or other) to try to keep the system memory from being
erased. The back–up power source may inadvertently power the SRS, and cause it to deploy.
(3) In minor collisions where the SRS does not deploy, the horn button assembly, instrument panel
passenger airbag assembly, front seat airbag assembly, curtain shield airbag assembly and seat
belt pretensioner should be inspected before further use of the vehicle (see pages 60–22, 60–34,
60–43, 60–48 and 61–11).
(4) Never use SRS parts from another vehicle. When replacing parts, use new parts.
(5) Before repairs, remove the airbag sensor if impacts are likely to be applied to the sensor during
repairs.
(6) Never disassemble and repair the airbag sensor assembly, horn button assembly, instrument
panel passenger airbag assembly, front seat airbag assembly, curtain shield airbag assembly
or seat belt pretensioner.
(7) Replace the center airbag sensor assembly, side airbag sensor assembly, horn button assembly
or the instrument panel passenger airbag assembly, front seat airbag assembly or curtain shield
airbag assembly if: 1) damage has occurred from being dropped, or 2) cracks, dents or other
defects in the case, bracket or connector are present.
(8) Do not directly expose the airbag sensor assembly, horn button assembly, instrument panel pas-
senger airbag assembly, front seat airbag assembly, curtain shield airbag assembly or seat belt
pretensioner to hot air or flames.
(9) Use a voltmeter/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting electri-
cal circuits.
(10) Information labels are attached to the SRS components. Follow the instructions on the labels.
(11) After work on the SRS is completed, check the SRS warning lamp (see page 05–1397).