2002 Toyota Prius Owners Manual

oil in small quantities at a time, checking the dipstick. The approximate quantity of oil needed to fill between the low level and the full level on the dipstick is indicated below for ref- erence. When the level reaches within the correct range, install the filler cap hand–tight. Oil quantity, L (qt., Imp. qt.):

1.5 (1.6, 1.3)

With the hybrid system at operating temperature and turned off, check the oil level on the dipstick. 1. To get a

the vehicle should be on a level spot. After turning off the hybrid system, wait a few min- utes for the oil to drain back into the bottom of the engine.

reading,

true

2. Pull out the dipstick, and wipe it clean

with a rag.

3. Reinsert the dipstick—push it in as far as it will go, or the reading will not be correct.

4. Pull the dipstick out and look at the oil

level on the end.

208

ENGINE OIL SELECTION Use API grade SJ “Energy–Conserving”, SL “Energy–Conserving” or ILSAC multi- grade engine oil. Recommended viscosity (SAE):

OIL05u

for good

SAE 5W–30 is the best choice for your vehicle, fuel economy, and good starting in cold weather. If you use SAE 10W–30 engine oil in extremely low temperatures, the engine may become difficult to start, so SAE 5W–30 engine oil is recommended.

82P103

API service symbol

Oil identification marks Either or both API registered marks are added to some oil containers to help you select the oil you should use. The API Service Symbol is located any- where on the outside of the container. The top portion of the label shows the oil quality by API (American Petroleum Insti- tute) designations such as SL. The center portion of the label shows the SAE viscos- ity grade such as SAE 5W–30. “Energy– Conserving” shown in the lower portion, indicates that the oil has fuel–saving ca- pabilities. The ILSAC (International Lubricant Stan- dardization and Approval Committee) Certi- fication Mark is displayed on the front of the container.

ILSAC certification mark

209

Checking the coolant level Look at the see–through coolant reser- voir when the hybrid system is cold. The coolant level is satisfactory if it is between the “FULL” and “LOW” lines on the reservoir. If the level is low, add ethylene–glycol type coolant for a prop- er corrosion protection of aluminum components. The coolant level in the reservoir will vary with hybrid system temperature. However, if the level is on or below the “LOW” line, add coolant. Bring to the “FULL” line. Always use ethylene–glycol type coolant for a proper corrosion protection of alumi- num components. See information in the next column. If the coolant level drops within a short time after replenishing, there may be a leak the radiator, hoses, radiator cap and drain cock and water pump. If you can find no leak, have your Toyota dealer test the cap pressure and check for leaks in the cooling system.

the system. Visually check

level up

the

in

210

We recommend to use 50% solution for your Toyota, to provide protection down to about –35°C (–31°F). When it is extremely cold, to provide protection down to about –50°C (–58°F), 60% solution is recom- mended. Do not use more than 70% solu- tion for better coolant performance.

NOTICE

Do not use alcohol type antifreeze or plain water alone.

CAUTION

To prevent burning yourself, do not remove the radiator cap when the en- gine is hot.

Coolant type selection Use of improper coolants may damage your cooling system. Your coolant must contain ethylene–glycol type coolant for a proper corrosion protection of your hybrid system that contains aluminum compo- nents. Use “TOYOTA Long Life Coolant” or equivalent. In addition to preventing freezing and sub- sequent damage to the hybrid system, this type of coolant will also prevent corrosion. Further supplemental inhibitors or additives are neither needed nor recommended. Read the coolant container for information on freeze protection. Follow the manufac- turer’s directions to mix with plain water (preferably demineralized water of distilled water). The total capacity of the cooling system is given on page 236 in Section 9.

for how much

Checking the radiator and condenser If any of the above parts are extremely dirty or you are not sure of their condi- tion, take your vehicle to Toyota dealer.

CAUTION

To prevent yourself from burning, be careful not to touch the radiator or condenser when the engine is hot.

NOTICE

To prevent damage to the radiator and condenser, do not perform the work by yourself.

Checking brake fluid

82p002a

reservoir. The

To check the fluid level, simply look at the see–through level should be between the ”MAX” and ”MIN” lines on the reservoir. It is normal for the brake fluid level to go down slightly as the brake pads wear or when the fluid level in the accumulator is high. If the reservoir needs frequent refueling, it may indicate a serious mechanical prob- lem.

If the level is low, add SAE J1703 or FMVSS No. 116 DOT 3 brake fluid to the brake reservoir. Refilling brake fluid: 1. Turn the ignition switch off. 2. Depress the brake pedal more than 40

times.

3. Remove

the reservoir cap by hand. Add brake fluid up to the ”MAX” line. If you do not follow the procedure above, the reservoir may overflow. Use only newly opened brake fluid. Once opened, brake fluid absorbs moisture from the air, and excess moisture can cause a dangerous loss of braking.

CAUTION

Take care when filling the reservoir because brake fluid can harm your eyes and damage painted surfaces. If fluid gets in your eyes, flush your eyes with clean water immediately. If you still feel uncomfortable with your eyes, go to the doctor.

211

Checking and replacing the air conditioning filter

NOTICE

If you spill the fluid, be sure to wipe it off to prevent it from damaging the parts or painting.

82p006a

27p007

1. Open the glove box. Turn and pull out 2 pins located on both sides. Pull down the glove box.

The air conditioning filter may clog af- ter long use. The filter may need to be replaced if the air flow of the air condi- tioning and heater experiences extreme reductions in operating efficiency, or if the windows become to fog up easily. The air conditioning filter is set behind the glove box. To maintain the air conditioning efficiency, inspect and replace the air conditioning filter according to the maintenance sched- ule.

212

82p008a

82p009a

2. Pull the filter case toward you to

take it out.

3. Remove the filter from the filter case

and replace it with a new one.

4. Install the filter and filter case in the

reverse order of removal.

Set the filter in the filter case correctly. INFORMATION: The air filter should be installed proper- ly in position. The use of air condition- ing with the air filter removed may cause deteriorated dustproof perfor- mance and then affect air conditioning performance.

213

Checking tire pressure

82p003

Keep your tire pressures at the proper level. The recommended cold tire pressures, tire size and the vehicle capacity weight are given on page 237 in Section 9. They are also on the tire pressure label as shown. You should check the tire pressures every two weeks, or at least once a month. And do not forget the spare! Incorrect tire pressure can reduce tire life and make your vehicle less safe to drive.

214

the

results

tire pressure

tire pressure

is excessively

Low in excessive wear, poor handling, reduced fuel econo- my, and the possibility of blowouts from overheated tires. Also, low tire pressure can cause poor sealing of the tire bead. If low, there is the possibility of wheel deforma- tion and/or tire separation. High tire pressure produces a harsh ride, handling problems, excessive wear at the center of the tire tread, and a greater possibility of tire damage from road haz- ards. If a tire frequently needs refilling, have it checked by your Toyota dealer. The following instructions for checking tire pressure should be observed: (cid:1) The pressure should be checked only when the tires are cold. If your vehicle has been parked for at least 3
hours and has not been driven for more than 1.5 km or 1 mile since, you will get an accurate cold tire pressure reading.

(cid:1) Always use a tire pressure gauge. The appearance of a tire can be mis- leading. Besides, that are even just a few pounds off can degrade ride and handling.

tire pressures

(cid:1) Take special care when adding air to the compact spare tire. The smaller tire size can gain pressure very quick- ly. Add compressed air in small quanti- ties and check the pressure often until it reaches the specified pressure.

(cid:1) Do not bleed or reduce tire pressure after driving. It is normal for the tire pressure to be higher after driving.

(cid:1) Never exceed

the vehicle capacity weight. The passenger and luggage weight should be located so that the vehicle is balanced.

(cid:1) Be sure to reinstall the tire inflation valve caps. Without the valve caps, dirt or moisture could get the valve core and cause air leakage. If the caps have been lost, have new ones put on as soon as possible.

into

Checking and replacing tires

Tread wear indicator

82p004b

CHECKING YOUR TIRES Check the tire tread for the tread wear indicators. If the indicators show, re- place the tires. The tires on your Toyota have built–in tread wear indicators to help you know when the tires need replacement. When the tread depth wears to 1.6 mm (0.06
in.) or less, the indicators will appear. If you can see the indicators in two or more adjacent grooves, the tire should be re- placed. The lower the tread, the higher the risk of skidding. The effectiveness of snow tires is lost if the tread wears down below 4 mm (0.16 in.).

Check the tires regularly for damage such as cuts, splits and cracks. If any damage is found, consult with a techni- cian and have the tire repaired or re- placed. Even if the damage does not appear seri- ous, a qualified technician should examine the damage. Objects which have pene- trated the tire may have caused internal damage. Any tires which are over 6 years old must be checked by a qualified techni- cian even if damage is not obvious. Tires deteriorate with age even have never or seldom been used. This also applies to the spare tire and tires stored for future use. REPLACING YOUR TIRES When replacing a tire, use only the same size and construction as original- ly installed and with the same or great- er load capacity. Using any other size or type of tire may seriously affect handling, ride, speedome- ter/odometer calibration, ground clearance, and clearance between the body and tires or snow chains.

they

if

CAUTION

(cid:1) Do not mix radial, bias belted, or bias–ply tires on your vehicle. It can cause dangerous handling char- acteristics, resulting in loss of con- trol.

(cid:1) Do not use tires or wheels other recom-

the manufacturer’s

than mended size.

NOTICE

Do not use tires of different brands, sizes and constructions. This may damage the drive system.

Toyota recommends all four tires, or at least both front or rear tires be re- placed as a set. See “If you have a flat tire” on page 173
in Section 5 for tire change procedure.

215

tire

the wheel

When a is replaced, should always be balanced. An unbalanced wheel may affect vehicle handling and tire life. Wheels can get out of balance with regular use and should therefore be balanced occasionally. When replacing a tubeless tire, the air valve should also be replaced with a new one.

rotating

tires, check

When for uneven wear and damage. Abnormal wear is usu- ally caused by incorrect tire pressure, im- proper wheel alignment, out–of–balance wheels, or severe braking.

CAUTION

Do not include a compact spare tire when rotating the tires. It is designed for temporary use only.

Rotating tires

82p104

To equalize tire wear and help extend tire life, Toyota recommends that you rotate your tires according to the main- tenance schedule. (For scheduled main- tenance information, please refer to the “Scheduled Maintenance Guide” or “Owner’s Manual Supplement”.) Howev- er, the most appropriate timing for tire rotation may vary according to your driving habits and road surface condi- tions. See “If you have a flat tire” on page 173
in Section 5 for tire change procedure.

216

Installing snow tires and chains WHEN TO USE SNOW TIRES OR CHAINS Snow tires or chains are recommended when driving on snow or ice. On wet or dry roads, conventional tires provide better traction than snow tires. SNOW TIRE SELECTION If you need snow tires, select the same size, construction and load capacity as the original tires on your Toyota. Do not use tires other than those men- tioned above. Do not install studded tires without first checking local regulations for possible restrictions.

SNOW TIRE INSTALLATION Snow tires should be installed on all wheels. Installing snow tires on the front wheels only can lead to an excessive difference in road grip capability between the front and rear tires which could cause loss of vehicle control. When storing removed tires, you should store them in a cool dry place. Mark the direction of rotation and be sure to install them in the same direction when replacing.

CAUTION

(cid:1) Do not drive with the snow tires

incorrectly inflated.

(cid:1) Never drive over 120 km/h (75 mph)

with any type of snow tires.

NOTICE

Do not attempt to use a tire chain on the compact spare tire, as it may re- sult in damage to the vehicles as well as the tire.

TIRE CHAIN SELECTION Use the tire chains of correct size. Regulations regarding the use of tire chains vary according to location or type of road, so always check them before installing chains. CHAIN INSTALLATION Install the chains on the front tires as tightly as possible. Do not use tire tires. Retighten chains on chains after km (1/4—1/2 mile). When installing chains on your tires, care- fully follow the instructions of the chain manufacturer. If wheel covers are used, they will be scratched by the chain band, so remove the covers before putting on the chains.

rear driving

0.5—1.0

the

217

Replacement with used wheels is not rec- ommended as they may have been sub- jected to rough treatment or high mileage and could fail without warning. Also, bent wheels which have been straightened may have structural damage and therefore should not be used. Never use an inner tube in a leaking wheel which is designed for a tubeless tire.

Replacing wheels WHEN TO REPLACE YOUR WHEELS If you have wheel damage such as bending, cracks or heavy corrosion, the wheel should be replaced. If you fail to replace damaged wheels, the tire may slip off the wheel or cause loss of handling control. WHEEL SELECTION When replacing wheels, care should be taken to ensure that the wheels are re- placed by ones with the same load ca- pacity, diameter, rim width, and offset. This must be observed on compact spare tire, too. Correct replacement wheels are available at your Toyota dealer. A wheel of a different size or type may adversely affect handling, wheel and bear- ing life, brake cooling, speedometer/odom- eter calibration, stopping ability, headlight aim, bumper height, vehicle ground clear- ance, and tire or snow chain clearance to the body and chassis.

CAUTION

(cid:1) Do not exceed 50 km/h (30 mph) or recom- is

the chain manufacturer’s mended speed lower.

limit, whichever

(cid:1) Drive carefully avoiding bumps, holes, and sharp turns, which may cause the vehicle to bounce.

(cid:1) Avoid sharp turns or locked–wheel braking, as use of chains may ad- versely affect vehicle handling.

(cid:1) When driving with chains installed, be sure to drive carefully. Slow down before entering the curves to avoid losing control of the vehicle. Otherwise an accident may occur.

NOTICE

Do not attempt to use a tire chain on the compact spare tire, as it may re- sult in damage to the vehicle as well as the tire.

218

Aluminum wheel precautions (cid:1) When aluminum wheels, check tight after driving your vehicle the first 1600
km (1000 miles).

the wheel nuts are

installing that

repaired, or (cid:1) If you have changed your the wheel nuts are still tight after driving 1600 km (1000 miles).

rotated, tires, check

that

(cid:1) When using tire chains, be careful not

to damage the aluminum wheels.

(cid:1) Use only the Toyota wheel nuts and for your aluminum

wrench designed wheels.

(cid:1) When balancing your wheels, use only Toyota balance weights or equivalent and a plastic or rubber hammer.

(cid:1) As with any wheel, periodically check your aluminum wheels for damage. If damaged, replace immediately.

219

220

SECTION 8– 3

DO–IT–YOURSELF MAINTENANCE Electrical components Checking auxiliary battery condition Auxiliary battery recharging precautionss Checking and replacing fuses Adding washer fluid Replacing light bulbs

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

222
223
223
225
225

221

Checking auxiliary battery condition— —Precautions

CAUTION

AUXILIARY BATTERY PRECAUTIONS When the auxiliary battery must be replaced, use the Prius designated battery. The auxiliary battery produces flam- mable and explosive hydrogen gas. (cid:1) Do not cause a spark from the bat-

tery with tools.

(cid:1) Do not smoke or light a match near

the battery.

The electrolyte contains poisonous and corrosive sulfuric acid. (cid:1) Avoid contact with eyes, skin or

clothes.

(cid:1) Never ingest electrolyte. (cid:1) Wear protective safety glasses when

working near the battery.

(cid:1) Keep children away from the bat-

tery.

222

EMERGENCY MEASURES (cid:1) If electrolyte gets

in your eyes, flush your eyes with clean water and get immediate medical atten- tion. If possible, continue to apply water with a sponge or cloth while en route to the medical office.

(cid:1) If electrolyte gets on your skin, thoroughly wash the contact area. If you feel pain or burn, get medical attention immediately.

(cid:1) If electrolyte gets on your clothes, there is a possibility of its soaking through to your skin, so immediate- ly take off the exposed clothing and follow the procedure above, if nec- essary.

(cid:1) If you accidentally swallow electro- lyte, drink a large quantity of water or milk. Follow with milk of magne- sia, beaten raw egg or vegetable oil. Then go immediately for emer- gency help.

(cid:1) Warning: Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause can- cer and reproductive harm. Wash hands after handling.

—Checking auxiliary battery exterior

Terminals

Ground cable

Hold–down clamp

Check the battery for corroded or loose terminal connections, cracks, or loose hold–down clamp. a. If the battery is corroded, wash it off with a solution of warm water and bak- ing soda. Coat the outside of the termi- nals with grease to prevent further cor- rosion.

b. If the terminal connections are loose, their clamp nuts—but do not

tighten overtighten.

c. Tighten

the hold–down clamp only enough to keep the battery firmly in place. Overtightening may damage the battery case.

NOTICE

(cid:2) Be sure the hybrid system and all accessories are off before perform- ing maintenance.

(cid:2) When checking the battery, remove the ground cable from the negative terminal (“—” mark) first and rein- stall it last.

(cid:2) Be careful not to cause a short cir-

cuit with tools.

(cid:2) Take care no solution gets into the

battery when washing it.

Auxiliary battery recharging precautions During recharging, the battery is pro- ducing hydrogen gas. Therefore, before recharging: 1. If recharging with the battery installed on the vehicle, be sure to disconnect the ground cable.

2. Make sure the power switch on the recharger is off when connecting the charger cables to the battery and when disconnecting them.

CAUTION

(cid:1) Always charge the battery in an un- confined area. Do not charge the battery in a garage or closed room where there is not sufficient ventila- tion.

(cid:1) Only do a slow charge (3.5A or less). Charging at a quicker rate is dangerous. The battery may ex- plode, causing personal injuries.

NOTICE

Never recharge the battery with the hybrid system on. Also, be sure all accessories are turned off.

Checking and replacing fuses

Type A

Good

Blown

Type B

83p003

Good

Blown

Type C

Good

Blown

223

the new

If fuse immediately blows out, there is a problem with the electrical sys- tem. Have your Toyota dealer correct it as soon as possible.

CAUTION

Never use a fuse with a higher am- perage rating, or any other object, in place of a fuse. This may cause ex- tensive damage and possibly a fire.

Type A fuses can be pulled out by the pull–out tool. The location of the pull–out tool is shown in the illustration. If you are not sure whether the fuse has blown, try replacing the suspected fuse with one that you know is good. If the fuse has blown, push a new fuse into the clip. Only install a fuse with the amperage rat- ing designated on the fuse box lid. If you do not have a spare fuse, in an emergency you can pull out the “DOME” or “OBDII” fuse, which may be dispens- able for normal driving, and use it if its amperage rating is the same. If you cannot use one of the same amper- age, use one that is lower, but as close as possible to, the rating. If the amperage is fuse might blow out again. but this does not indicate anything wrong. Be sure to get the correct fuse as soon as possible and return the substitute to its original clip. It is a good idea to purchase a set of spare fuses and keep them in your ve- hicle for emergencies.

that specified,

lower

than

the

83p004a

If the headlights or other electrical components do not work, check the fuses. If any of the fuses are blown, they must be replaced. See “Fuse locations” on page 201 in Sec- tion 8–1 for locations of the fuses. Turn the ignition switch and inoperative component off. Pull a suspected fuse straight out and check it. Determine which fuse may be causing the problem. The lid of the fuse box shows the name of the circuit for each fuse. See page 237 in Section 9 for the functions controlled by each circuit.

224

Adding washer fluid

83p009

NOTICE

Do not use engine antifreeze or any other substitute because it may dam- age your vehicle’s paint.

If any washer does not work, the wash- er tank may be empty. Check the wash- er fluid level on the level gauge. If the washer fluid level is below “LOW”, add washer fluid. FULL” on the side of the washer tank “ indicates the full level of washer fluid. Do not refill washer fluid over this level. You may use plain water as washer fluid. in cold areas where tempera- However, tures freezing point, use washer fluid containing antifreeze. This product is available at your Toyota dealer and most auto parts stores. Follow the manufacturer’s directions for how much to mix with water.

range below

following

illustrations show how

Replacing light bulbs— The to gain access to the bulbs. When replacing a bulb, make sure the ignition switch and light switch are off. Use bulbs with the wattage ratings given in the table.

CAUTION

(cid:1) To prevent yourself from burning, do not replace the light bulbs while they are hot.

(cid:1) Halogen bulbs have pressurized gas inside and require special handling. They can burst or shatter if scratched or dropped. Hold a bulb only by its plastic or metal case. Do not touch the glass part of a bulb with bare hands.

NOTICE

Only use a bulb of the listed type.

225

the

fogging

The inside of the lens of exterior lights such as headlights may temporarily fog up when the lense becomes wet in the rain or in a car wash. This is not a problem because the temperature difference between the outside and the windshield fogged up in the rain. However, if there is a large drop of water on the inside of the lense, or if there is water pooled light, contact your Toyota dealer.

is caused by

inside of

lense,

inside

just

like

the

the

Light bulbs

Headlights Parking lights Front turn signal lights Rear turn signal lights Stop and tail lights Back–up lights License plate lights High mounted stop- light Interior light Personal light Trunk light

Bulb No. — 60/55
947

—

21

7440
7443
921
—

9419

— — 194

21
21/5
16

3.8

A: HB2 Halogen bulbs B: Single end bulbs C: Wedge base bulbs D: Double end bulbs

226

Type

—Headlights

83p010

1. Open the hood.

RIGHT–HAND HEADLIGHT: Remove the clip and take out the air cleaner inlet. Remove and install the clip as shown in the following illustration. LEFT–HAND HEADLIGHT: Remove the upper part of the washer fluid reser- voir while pinching the lever.

83p011

83p013

83p014

Removing clip

83p012

Installing clip

2. Unplug the connector. Remove the

rubber cover.

If the connector is tight, wiggle it.

3. Release

the bulb retaining spring and remove the bulb along with the socket. Install a new bulb into the socket and return the bulb retaining spring to its original position.

To install a bulb, align the tabs of the bulb with the cutout of the mounting hole.

227

—Parking lights

—Front turn signal lights

83p015a

83p016

83p010

4. Install the rubber cover as shown, and snuggle on the boss. Plug in the connector.

Make sure the rubber cover fits snugly on the connector and the headlight body. Aiming is not necessary after replacing the bulb. When aiming adjustment is nec- essary, contact your Toyota dealer.

83p017

RIGHT–HAND FRONT TURN SIGNAL LIGHT: Remove the clip and take out the air cleaner inlet. Remove and install the clip as shown in the following illustration. LEFT–HAND FRONT TURN SIGNAL: Re- move the upper part of the washer fluid reservoir while pinching the lever.

228

—Rear turn signal, stop/tail and back–up lights

83P011

83p018

83p023

Removing clip

83p012

83p019

83p029

Installing clip

229

—High mounted stoplight

83p025

83p005

83p007

a: Tail light b: Rear turn signal light c: Back–up light d: Stop/tail light

Use a flat–bladed screwdriver.

Use a flat–bladed screwdriver.

83p006

83p008

230

Use a Phillips–head screwdriver.

—License plate lights

83p026

83p028a

Remove the cover clips.

83p027

231

232