For All Of Vehicles: Precaution

1. Engineers to be engaged in inspection and servicing related to high-voltage systems should undergo special training.
2. All the high-voltage wire harness connectors are colored orange: the HV battery and other high-voltage components are identified by the "High Voltage" caution labels. Do not carelessly touch these wires and components.
   Fig 1: Removing Service Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Before inspecting or servicing the high-voltage system, be sure to take 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.
NOTE: The 5 minutes are required to discharge the high-voltage condenser inside the inverter.
4. After removing the service plug, wait 5 minutes before touching any of the high-voltage connectors and terminals.
5. Before wearing insulated gloves, make sure that they are not cracked, ruptured, torn, or damaged in any other way. Do not wear wet insulated gloves.
6. When servicing the vehicle, do not wear a metal object like a mechanical pencil or scale that may drop accidentally and cause a short circuit.
7. Before touching a bare high-voltage terminal, wear insulated gloves and ensure that the terminal is not charged with electricity (approx. 0 V) using an electrical tester.
   Fig 2: Insulating High Voltage Connector With Tape

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. After disconnecting or exposing a high-voltage connector or terminal, insulate it immediately using insulation tape.
9. The screw of a high-voltage terminal should be tightened firmly to the specified torque. Both insufficient and excessive tightening torque can cause failure.
10. Call other engineers' attention to the vehicle which high-voltage system is being inspected or repaired by hanging a "High Voltage Operation in Progress. Do Not Touch" sign (See Fig 3).
11. 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 engaged.

Fig 3: High Voltage Circuit Inspection And Service

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 4: Precautions For Servicing Or Inspecting Engine Compartment

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.

NOTE: The following phenomena indicate that the auxiliary battery is depleted:
NOTE: Never use a quick charger.
1. Actions to be taken when 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.
   1. Move the shift lever to the P position, and engage the parking brake.
   2. Remove the ignition key plate from the ignition switch.
      Fig 5: Charging Auxiliary Battery

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Using a booster cable, connect the 12 V battery of the rescue vehicle and auxiliary battery of the stalled vehicle.
   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.
      Fig 6: Identifying Battery Warning Light

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the hybrid system fails to start and the master and HV battery warning lights come on, the HV battery may have been discharged.

   NOTE: If the auxiliary battery needs to be replaced, replace it only with a 12 V battery specially designed for the use of the PRIUS.
   6. Disconnect the booster cable in the reverse way of the connection procedure.
2. Actions to be taken when HV battery is depleted

Fig 7: Identifying Hybrid System Error Warning Light

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Activation inspection mode (Without using a hand-held tester)

1. Perform the following (2) through (6) within 60 sec.
2. Turn the ignition switch ON from OFF.
3. With the shift lever in P position, fully depress the accelerator pedal 2 times.
4. With the shift lever in N position, fully depress the accelerator pedal 2 times.
5. With the shift lever in P position, fully depress the accelerator pedal 2 times.
6. Activate the inspecting mode and check that the hybrid system error warning light on the multi-center display flashes.
NOTE: 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.
7. Turning the ignition switch to START starts the engine's continuous operation.

1. 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:
      Fig 8: Identifying Shift Lever Position For Test

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Traveling on a road without resetting the service mode may damage the transaxle.
   3. Reset the service mode immediately after completion of inspection.
NOTE: Rapid starting or quick acceleration/deceleration based on the speedometer tester without load setting may damage the transaxle.
2. Special notes for speedometer test
   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.
3. Special note for using the chassis dynamometer Always set an appropriate load before starting the test.

1. 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
2. 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. See Fig 9.
      Fig 9: Identifying High Voltage Part And Wiring

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • 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.
     Fig 10: Removing Service Plug

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • Remove the service plug with the insulated gloves on.
   Fig 11: Identifying HV Fuse And IGCT Relay On Engine Room J/B

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   If the service plug cannot be removed due to damage to the rear portion of the vehicle, remove the HV fuse or IGCT relay instead.

NOTE: 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.
  Fig 12: Identifying Ready Light

  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
• The READY light is not lit when you turn ignition key to the ON position.
NOTE:
• 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:
3. Moving the damaged vehicle
   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.
4. 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.

5. 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
6. 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 reapply 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.
7. 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.
NOTE: 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.
8. Precautions to be observed when towing

   Tow the damaged vehicle with its front wheels or its front and rear wheels lifted off the ground.

NOTE:
• 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.
Fig 13: Identifying Point For Towing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Towing with 4 wheels on the ground
10. Towing eyelet
    1. Install the hook.
    2. Hook a rope onto the illustrated point for towing.

1. 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.

   Fig 14: Disconnecting Negative Cable

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. 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 RETRIEVING CODES .
   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 AIR BAG RESTRAINT SYSTEMS .
   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 kΩ/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. AIR BAG RESTRAINT SYSTEMS .
   Fig 15: Identifying Marks For Correct Steering Wheel Installation

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. 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.

4. 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 AIR BAG RESTRAINT SYSTEMS .

      Carry out the operation in a safe place away from electrical noise.

      Fig 16: Identifying Correct Steering Wheel Pad Position

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 17: Warning Never Measure Resistance Of Airbag Squib

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. 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 AIR BAG RESTRAINT SYSTEMS .

      Perform the operation in a safe place away from electrical noise.

      Fig 18: Identifying Correct Position Of Front Passenger Airbag Assembly For Storing

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 19: Warning Never Measure Resistance Of Airbag Squib

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. 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 AIR BAG RESTRAINT SYSTEMS .

      Perform the operation in a safe place away from electrical noise.

      Fig 20: Identifying Correct Position Of Side Airbag Assembly For Storing

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 21: Warning Never Measure Resistance Of Airbag Squib

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Seat Belt Pretensioner
   1. Never measure the resistance of the seat belt pretensioner. (This may cause the seat belt pretensioner 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. 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.
   Fig 22: Warning Never Measure Resistance Of Seat Belt Pretensioner

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. 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.
9. 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. See AIR BAG RESTRAINT SYSTEMS .

1. Use only unleaded gasoline.
2. Avoid prolonged idling.

   Avoid running the engine at idle speed for more than 20 minutes.

3. 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.
4. Avoid prolonged engine compression measurement.

   Engine compression tests must be done as rapidly as possible.

5. 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.

6. Avoid coasting with ignition turned off.
7. Do not dispose of used catalyst along with parts contaminated with gasoline or oil.

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.