Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2006 Toyota PriusFACTORY OEM SERVICE PROCEDURE
Repair Instruction: Precaution
- BASIC REPAIR HINT
- HINTS ON OPERATIONSBASIC REPAIR HINT
1 Attire - 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 operation. 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 the operation, prepare a tool stand, SST, gauge, oil and parts for replacement. 5 Removal and installation, disassembly operations - Diagnose with a thorough understanding of proper procedures and of the reported problem.
- Before removing 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 ensure reassembly of components to their 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 removed parts in a separate box to avoid mixing them up with new parts or contaminating new parts.
- For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them with new ones as instructed in the article.
- Retain the removed parts for customer inspection, if requested.
- JACKING UP AND SUPPORTING VEHICLE
- Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations.
- PRECOATED PARTS
- Precoated parts are bolts and nuts that are coated with a seal lock adhesive at the factory.
- If a precoated part is retightened, loosened or moved in any way, it must be recoated with the specified adhesive.
- When reusing a precoated part, clean off the old adhesive and dry the part with compressed air. Then apply new seal lock adhesive appropriate to that part.
- Some seal lock agents harden slowly. You may have to wait for the seal lock adhesive to harden.
- GASKETS
- When necessary, use a sealer on gaskets to prevent leaks.
- BOLTS, NUTS AND SCREWS
- Carefully follow all the specifications for tightening torques. Always use a torque wrench.
- FUSES
- When inspecting a fuse, check that the wire of the fuse is not broken.
- When replacing fuses, be sure that the new fuse has the correct amperage rating. Do not exceed the rating or use one with a lower rating.ILLUSTRATION AND SYMBOLS REFERENCE
Illustration Symbol Part Name Abbreviation FUSE FUSE MEDIUM CURRENT FUSE M-FUSE HIGH CURRENT FUSE H-FUSE FUSIBLE LINK FL CIRCUIT BREAKER CB
- CLIPS
- The removal and installation methods of typical clips used for vehicle body parts are shown in the table below.
HINT:
If clips are damaged during a procedure, always replace the clips with new clips.
CLIP REMOVAL AND INSTALLATION METHODSShape (Example) Illustration Procedures Remove the clips with a clip remover or pliers. Remove the clips with a clip remover or screwdriver. Remove the clips with a wide scraper to prevent panel damage. Remove the clips by pushing center pin through and prying out the shell. Remove the clips by unscrewing the center pin and prying out the shell. Remove the clips by prying out the pin and then prying out the shell.
- The removal and installation methods of typical clips used for vehicle body parts are shown in the table below.
- CLAWS
- The removal and installation methods of typical claws used for vehicle body parts are shown in the table below.
HINT:
If claws of caps or covers are damaged during a procedure, always replace the caps or covers with new ones.
CLIP REMOVAL AND INSTALLATION METHODSShape (Example) Illustration Procedures 1. Using a screwdriver, detach the claws and remove the cap or cover. Using a screwdriver, detach the claws and remove the cap or cover. Using a screwdriver, detach the claws and remove the cap or cover.
- The removal and installation methods of typical claws used for vehicle body parts are shown in the table below.
- REMOVAL AND INSTALLATION OF VACUUM HOSES
- To disconnect a vacuum hose, pull and twist from the end of the hose. Do not pull from the middle of the hose as this may cause damage.
- When disconnecting vacuum hoses, use tags to identify where they should be reconnected.
- After completing any hose related repairs, double check that the vacuum hoses are properly connected. The label under the hood shows the proper layout.
- When using a vacuum gauge, never force the hose onto a connector that is too large. If a hose has been stretched, it may leak air. Use a step-down adapter if necessary.
- TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL
- Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with the torque wrench.
Formula: T' = L2 / (L1 + L2) * T
TORQUE WRENCH LENGTHT' Reading of torque wrench {N*m (kgf*cm, ft.*lbf)} T Torque {N*m (kgf*cm, ft.*lbf)} L1 Length of SST or extension tool {cm (in.)} L2 Length of torque wrench {cm (in.)}
- Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with the torque wrench.
- HINTS ON OPERATIONS
Factory Service Tools
Use the Manual With the Right Hardware
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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