Toyota Prius 2004 Repair Workshop Manual PDF

010RZ–01
B73283
1
2
3
4
5
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INTRODUCTION REPAIR INSTRUCTION
01–5
5Author: Date:
2004 PRIUS REPAIR MANUAL (RM1075U)
REPAIR INSTRUCTION
PRECAUTION
1. BASIC REPAIR HINT
(a) HINTS ON OPERATIONS
1 Looks
Always wear a clean uniform.
A hat and safety shoes must be worn.
2 Vehicle protection Prepare a grille cover, fender cover, seat cover and floor mat before starting the repairs.
3 Safe operation
When working with 2 or more persons, be sure to check safety for one another.
When working with the engine running, make sure to provide ventilation for exhaust fumes in the
workshop.
If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety
equipment and take extra care not to injure yourself or others.
When jacking up the vehicle, be sure to support the specified location with a safety stand.
When lifting up the vehicle, use appropriate safety equipment.
4
Preparation of tools and
measuring gauge
Before starting operation, prepare a tool stand, SST, gauge, oil, shop rag and parts for replacement.
5
Removal and installation,
disassembly and assem-
bly operations
Diagnose with a thorough understanding of proper procedures and of the reported problem.
Before removing the parts, check the general condition of the assembly and for deformation and damage.
When the assembly is complicated, take notes. For example, note the total number of electrical connections,
bolts, or hoses removed. Add matchmarks to insure re–assembly of components in the original positions.
Temporarily mark hoses and their fittings, if needed.
Clean and wash the removed parts if necessary and assemble them after a thorough check.
6 Removed parts
Place the removed parts in a separate box to avoid mixing them up with the new parts or contaminating the
new parts.
For non–reusable parts such as a gasket, O–ring, and self–locking nut, replace them with new ones following
the instructions in this manual.
Retain the removed parts for customer inspection, if requested.

Toyota Prius 2004 Repair Workshop Manual Summary of Content

010RZ01B73283123456INTRODUCTION REPAIR INSTRUCTION0155Author: Date:2004 PRIUS REPAIR MANUAL (RM1075U)REPAIR INSTRUCTIONPRECAUTION1. BASIC REPAIR HINT(a) HINTS ON OPERATIONS1 Looks Always wear a clean uniform. A hat and safety shoes must be worn.2 Vehicle protection Prepare a grille cover, fender cover, seat cover and floor mat before starting the repairs.3 Safe operation When working with 2 or more persons, be sure to check safety for one another. When working with the engine running, make sure to provide ventilation for exhaust fumes in theworkshop. If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety equipment and take extra care not to injure yourself or others. When jacking up the vehicle, be sure to support the specified location with a safety stand. When lifting up the vehicle, use appropriate safety equipment.4Preparation of tools andmeasuring gauge Before starting operation, prepare a tool stand, SST, gauge, oil, shop rag and parts for replacement.5Removal and installation,disassembly and assem-bly operations Diagnose with a thorough understanding of proper procedures and of the reported problem. Before removing the parts, check the general condition of the assembly and for deformation and damage. When the assembly is complicated, take notes. For example, note the total number of electrical connections,bolts, or hoses removed. Add matchmarks to insure reassembly of components in the original positions.Temporarily mark hoses and their fittings, if needed. Clean and wash the removed parts if necessary and assemble them after a thorough check.6 Removed parts Place the removed parts in a separate box to avoid mixing them up with the new parts or contaminating thenew parts. For nonreusable parts such as a gasket, Oring, and selflocking nut, replace them with new ones followingthe instructions in this manual. Retain the removed parts for customer inspection, if requested.