01±5
INTRODUCTION ± REPAIR INSTRUCTION
REPAIR INSTRUCTION
010RZ±01
PRECAUTION
1.BASIC REPAIR HINT
(a)HINTS ON OPERATIONS
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B73283 |
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1 |
Looks |
Always wear a clean uniform. |
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A hat and safety shoes must be worn. |
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Vehicle protection |
Prepare a grille cover, fender cover, seat cover and floor mat before starting the repairs. |
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When working with 2 or more persons, be sure to check safety for one another. |
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When working with the engine running, make sure to provide ventilation for exhaust fumes in the |
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workshop. |
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Safe operation |
If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety |
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equipment and take extra care not to injure yourself or others. |
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When jacking up the vehicle, be sure to support the specified location with a safety stand. |
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When lifting up the vehicle, use appropriate safety equipment. |
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Preparation of tools and |
Before starting operation, prepare a tool stand, SST, gauge, oil, shop rag and parts for replacement. |
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measuring gauge |
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Diagnose with a thorough understanding of proper procedures and of the reported problem. |
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Removal and installation, |
Before removing the parts, check the general condition of the assembly and for deformation and damage. |
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When the assembly is complicated, take notes. For example, note the total number of electrical connections, |
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disassembly and assem- |
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bolts, or hoses removed. Add matchmarks to insure re±assembly of components in the original positions. |
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bly operations |
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Temporarily mark hoses and their fittings, if needed. |
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Clean and wash the removed parts if necessary and assemble them after a thorough check. |
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Place the removed parts in a separate box to avoid mixing them up with the new parts or contaminating the |
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new parts. |
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Removed parts |
For non±reusable parts such as a gasket, O±ring, and self±locking nut, replace them with new ones following |
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the instructions in this manual. |
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Retain the removed parts for customer inspection, if requested. |
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2004 PRIUS REPAIR MANUAL |
(RM1075U) |
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Author : |
Date : |
5 |
01±6
INTRODUCTION ± REPAIR INSTRUCTION
(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 specified adhesive.
Seal Lock Adhesive
(3) When reusing precoated parts, clean off the old adhesive and dry the part with compressed air.
Z11554 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.
Medium Current Fuse and High Current
Fuse |
Equal Amperage Rating |
(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.
BE1367
Illustration |
Symbol |
Part Name |
Abbreviation |
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FUSE |
FUSE |
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MEDIUM CURRENT FUSE |
M±FUSE |
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HIGH CURRENT FUSE |
H±FUSE |
V35002
2004 PRIUS REPAIR MANUAL (RM1075U)
Author : |
Date : |
6 |
01±7
INTRODUCTION ± REPAIR INSTRUCTION
(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.
Shape (Example) |
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Removal/Installation |
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Clip |
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Pliers |
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Clip Remover |
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Remove clips from front or rear using clip remover |
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or pliers. |
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Protective Tape |
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Screwdriver
Remove fasteners with a clip remover or screwdriver.
Protective Tape
Scraper
Remove clips with a wide scraper to prevent panel damage.
D25786
2004 PRIUS REPAIR MANUAL (RM1075U)
Author : |
Date : |
7 |
01±8
INTRODUCTION |
± REPAIR INSTRUCTION |
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Shape (Example) |
Removal/Installation |
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Removal |
Installation |
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Screwdriver |
Push |
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Clip Remover
Remove rivet by pushing the center pin through and prying out the rivet shell.
Removal |
Installation |
Screwdriver
Push
Clip Remover
Remove rivet by unscrewing the center pin and prying out the rivet shell.
Removal |
Installation |
Push
Screwdriver
Clip Remover
Small Clip Remover
Remove rivet by prying out the pin and then prying out the rivet shell.
V35006
2004 PRIUS REPAIR MANUAL (RM1075U)
Author : |
Date : |
8 |
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01±9 |
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INTRODUCTION ± |
REPAIR INSTRUCTION |
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(h) REMOVAL AND INSTALLATION OF VACUUM HOSES |
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INCORRECT |
CORRECT |
(1) |
To disconnect vacuum hoses, pull and twist from |
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the end of the hose. Do not pull from the middle of |
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the hose as this may cause damage. |
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D31750
D25064
L1 |
L2 |
D02612
L1 |
L2 |
(2)When disconnecting vacuum hoses, use tags to identify where they should be reconnected.
(3)After completing the job, double check that the vacuum 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 EXTENSION 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' |
Reading of torque wrench {N m (kgf cm, ft lbf)} |
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T |
Torque {N m (kgf cm, ft lbf)} |
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L1 |
Length of SST or extension tool (cm) |
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L2 |
Length of torque wrench (cm) |
D01201
2004 PRIUS REPAIR MANUAL (RM1075U)
Author : |
Date : |
9 |
01±10
INTRODUCTION ± REPAIR INSTRUCTION
A83545
DO NOT WEAR
B76060
D32047
2.PRECAUTIONS FOR HIGH±VOLTAGE CIRCUIT IN-
SPECTION AND SERVICE
(a)Engineer must undergo special training to be able to perform high±voltage system inspection and servicing.
(b)All high±voltage wire harness connectors are colored orange. The HV battery and other high±voltage components have ºHigh Voltageº caution labels. Do not carelessly touch these wires and components.
(c)Before inspecting or servicing the high±voltage system, be sure to follow safety 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.
(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 condenser inside the inverter.
(e)Be sure to install the service plug before starting the hybrid 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 accidentally and cause a short circuit.
(h)Before touching a bare high±voltage terminal, wear insulated 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 connector 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 excessive torque can cause failure.
(k)Use the ºCAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATIONº sign to notify other engineers that a high±voltage system is being inspected and/or repaired.
(l)Do not place the battery upside down while removing and installing it.
2004 PRIUS REPAIR MANUAL (RM1075U)
Author : |
Date : |
10 |
01±11
INTRODUCTION ± REPAIR INSTRUCTION
(m)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 connected.
2004 PRIUS REPAIR MANUAL (RM1075U)
Author : |
Date : |
11 |
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