Person in charge

Copy this page and put it after folding on the roof of the vehicle in service.

B12120

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.

3. ACTIONS TO BE TAKEN WHEN BATTERIES ARE DEPLETED

(a) Actions to be taken when the auxiliary battery is depleted 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.

A

1^1 MAIN

N

B04750

(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) Turn the ignition switch of the stalled vehicle to the START position to start the hybrid system.

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.

(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.

MPH BBSSISL E!

MPH BBSSISL E!

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. Turn the ignition switch ON from OFF. With the shift lever in P position, fully depress the accelerator pedal 2 times.

With the shift lever in N position, fully depress the accelerator pedal 2 times.

With the shift lever in P position, fully depress the accelerator pedal 2 times.

Activate the inspecting mode and check that the hybrid system error warning light on the multi-center display flashes.

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.

B04762

* 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. SPECIAL NOTES FOR VEHICLE INSPECTION

(a) 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.

(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.

6. ACTIONS TO BE TAKEN FOR VEHICLE DAMAGED BY

IMPACT

(a) 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

(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 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.

(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.

• Remove the service plug with the insulatec gloves on.

If the service plug cannot be removed Cue 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.

• 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.

(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 reap-ply 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.

(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.

7. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER

(a) 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.

(b) 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-509).

(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.

(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 kQ/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-509).

(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-16 of this manual concerning correct steering wheel installation.

(d) 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 air-bag 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.

(e) FRONT PASSENGER AIRBAG ASSEMBLY

(1) Always store a removed or new front passenger air-bag 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 air-bag 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.

(f) 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 air-bag 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.

(g) SEAT BELT PRETENSIONER

(1) Never measure the resistance of the seat belt pre-tensioner. (This may cause the seat belt pretension-er 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.

(h) 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.

(i) 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.

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 handheld 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.

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