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.
2012 Toyota Prius ThreeFACTORY OEM SERVICE PROCEDURE
Repair Instruction: Precaution: Precaution
- BASIC REPAIR HINT
- HINTS ON OPERATIONS
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 work. 3 Safety procedures - When working with 2 or more persons, be sure to check the safety of 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 locations with safety stands.
- When lifting up the vehicle, use appropriate safety equipment.
4 Preparation of tools and measuring equipment Before starting work, prepare a tool stand, SST, measuring equipment, oil, and any replacement parts required. 5 Removal and installation, disassembly and assembly operations - Diagnose with a thorough understanding of proper procedures and of the reported problem.
- Before removing any parts, check the general condition of the assembly and for deformation and damage.
- If the procedure is complicated, take notes. For example, note the total number of electrical connections, bolts, or hoses removed. Add matchmarks to ensure 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 new parts or contaminating the new parts.
- For non-reusable parts such as gaskets, O-rings and self-locking nuts, replace them with new ones as instructed in this article.
- Retain the removed parts for customer inspection, if requested.
7* Checks to perform after work is finished - Make sure that removed and installed parts (oil filler cap, level dipstick, floor mat, etc.) are properly installed/tightened.
- Make sure that none of the cloths or tools that were used have been left in the engine compartment or within the vehicle.
- Check that there are no oil leaks.
WARNING:*: Be sure to perform these checks properly, Not performing these checks properly after finishing work can lead to serious accident or injury.
- 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 PARTSTEXT IN ILLUSTRATION
*1 Seal Lock Adhesive - Precoated parts are bolts and nuts that are coated with 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 appropriately 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 torque. Always use a torque wrench.
- FUSESTEXT IN ILLUSTRATION
*1 INCORRECT *2 CORRECT - When inspecting a fuse, check that the wire of the fuse is not broken.
- If the wire of a fuse is broken, confirm that there are no shorts in its circuit.
- When a fuse is replaced, a fuse with the same amperage rating must be used.
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 damaged clips with new ones.
Shape (Example) Removal/Installation
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 the 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 are damaged during a procedure, always replace the cap or cover that has damaged claws with a new one.
Shape (Example) Illustration Procedure Using a screwdriver, disengage the claws and remove the cap or cover. Using a screwdriver, disengage the claws and remove the cap or cover. Using a screwdriver, disengage 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.
- HINGES, GUIDES, CLAMPS, PINS, ETC.
- REMOVAL AND INSTALLATION OF VACUUM HOSES
- To disconnect a vacuum hose, pull and twist it from the end of the hose. Do not pull it from the middle of the hose as this may damage the hose.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
TEXT IN ILLUSTRATION*1 INCORRECT *2 CORRECT - 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, air may leak. Use a step-down adapter if necessary.
- To disconnect a vacuum hose, pull and twist it from the end of the hose. Do not pull it from the middle of the hose as this may damage the hose.
- 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 a torque wrench.
- Formula
T' = (L2/(L1 + L2))*T
T' 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.)}
NOTE:If an extension tool or SST is combined with a torque wrench and used to tighten to a torque specification in this article, the actual torque will be excessive and parts will be damaged.
- Formula
- Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with a torque wrench.
- HINTS ON OPERATIONS
- PRECAUTIONS FOR HIGH-VOLTAGE CIRCUIT INSPECTION AND SERVICE WARNING:
The vehicle has a hybrid system that operates at voltages up to 650 V. The hybrid system uses an HV battery that contains an electrolyte which is a strong alkali solution that includes potassium hydroxide. Be sure to follow the instructions in this article to handle the system correctly. Failure to do so may result in serious injury or electrocution.
- Technicians must undergo special training to be able to service and inspect the high-voltage system.
- All high-voltage wire harnesses and connectors are colored orange. The HV battery and other high-voltage components have "High Voltage" caution labels. Do not carelessly touch these wires or components.
- When there is a problem with the wire harness or connector of a high-voltage circuit, repairs to the harness or connector should not be attempted. Replace damaged or malfunctioning high voltage cables or connectors.
- Before inspecting or servicing the high-voltage system, be sure to follow all safety measures, such as wearing insulated gloves and removing the service plug to prevent electrocution. Carry the removed service plug in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle.
Factory Service Tools
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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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