Toyota Prius Repair Manual 2001-2008

SKU: CH68650-008
Toyota Prius Repair Manual 2001-2008
Toyota Prius Repair Manual 2001-2008
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Item Description

This Chilton repair and service manual covers Toyota Prius hybrid cars, all U.S. and Canadian models, 2001-2008.

Book Excerpt: 2001-2008 Toyota Prius Repair Manual


  • WARNING 1: Refer to Section 2 and follow all safety precautions before working on this system.
  • WARNING 2: Wait until the vehicle is completely cool before beginning this procedure.
  1. Refer to Chapter 6 and disconnect the cable from the negative terminal of the auxiliary 12-volt battery. Be sure to perform the initialization procedure when reconnecting it.
  2. Remove the high-voltage safety plug (see Section 2). Be sure to wait at least five minutes before proceeding. Drain the coolant from the inverter/converter/transaxle cooling system (see Chapter 1).
  3. Disconnect the battery cable from the inverter/converter. Cover it with vinyl electrical tape.
  4. Remove the four small Torx-head screws from the cover.
  5. Remove the two larger Torx-head screws from the circuit breaker sensor and connector cover.
  6. Use a voltmeter to test for voltage between each pair of the three terminals and also between each terminal and a good ground.

    The meter must read approximately zero volts everywhere. If not, wait for the system to discharge further. When all points read zero volts, proceed.

  7. Remove the six bolts and disconnect the three cables for motor/generator #2.
  8. Remove the three bolts and the cable from motor/generator #1. You will remove the cable along with the inverter/converter later.
  9. Remove the bolt and ground cable.
  10. Place rags around the inverter/converter to catch coolant. Disconnect the three coolant hoses from the assembly.
  11. Remove the four mounting bolts and lift off the inverter/converter assembly.
  12. Installation is the reverse of removal. Be sure to refill the cooling system (see Chapter 1).

  1. All models are equipped with a distributorless ignition system. The ignition system consists of the battery, ignition coils, spark plugs, camshaft position sensor, crankshaft position sensor and the Engine Control Module (ECM).

    The ECM controls the ignition timing and spark advance characteristics for the engine. The ignition timing is not adjustable. The intake camshaft timing is also controlled by the ECM.

  2. The crankshaft position sensor and camshaft position sensor generate pulses that are input to the Engine Control Module. The ECM determines piston position and engine speed from these two sensors.

    The ECM calculates injector sequence and ignition timing from the piston position. Refer to Chapter 6 for testing and replacement procedures for the crankshaft position sensor and camshaft position sensor.

  3. These models utilize an individual ignition coil for each cylinder. The unit is positioned directly over each spark plug. The ECM fires each coil sequentially in the firing order sequence.
  4. The ECM controls the ignition system by opening and closing the primary ignition coil control circuit. The computerized ignition system provides complete control of the ignition timing by determining the optimum timing in response to engine speed, coolant temperature, throttle position and engine load.

    These parameters are relayed to the ECM by the camshaft position sensor, crankshaft position sensor, throttle position sensor, coolant temperature sensor and manifold absolute pressure sensor or mass airflow sensor.

Subject: 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008 Toyota Prius Hybrid service, maintenance, repair. ISBN-10: 1563926911 | ISBN-13: 9781563926914 | Chilton 68650

  • Publisher: Chilton Manuals
  • Pages: 344 - Hundreds of b&w photos and illustrations
  • Binding: Paperback - 8.5 x 11 inches
  • ISBN: 978-1-56392-691-4
  • Years: 2001 - 2008
Table of Contents
TABLE of CONTENTS: Introduction: About this manual | Introduction | Vehicle identification numbers | Maintenance techniques, tools and working facilities | Buying parts | Jacking and towing | Booster battery (jump) starting | Conversion factors | Automotive chemicals and lubricants | Safety first! | Troubleshooting
  • Tune-up and routine maintenance
  • Engine and overhaul procedures
  • Cooling, heating and air-conditioning systems
  • Fuel and exhaust systems
  • Engine electrical systems
  • Emissions control systems
  • Transmission
  • Brakes
  • Suspension and steering systems
  • Body
  • Chassis electrical system
  • Wiring diagrams
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