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
01–2 –INTRODUCTION 2004 Prius – Preliminary Release (RM1075U)
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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
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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.