–INTRODUCTION REPAIR INSTRUCTION
2004 PRIUS REPAIR MANUAL (RM1075U)
1. BASIC REPAIR HINT
(a) HINTS ON OPERATIONS
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
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.
Preparation of tools and
Before starting operation, prepare a tool stand, SST, gauge, oil, shop rag and parts for replacement.
Removal and installation,
disassembly and assem-
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
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.