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    Toyota Prius Service Repair Manual 2004-2009

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    This manual covers the 2004-2009 Prius, the second generation of its groundbreaking hybrid vehicle. Known for its pioneering Hybrid Synergy Drive system, the Prius has set standards in fuel efficiency...
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    Typ: Car
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    Art.-Nr: 104940
    This manual covers the 2004-2009 Prius, the second generation of its groundbreaking hybrid vehicle. Known for its pioneering Hybrid Synergy Drive system, the Prius has set standards in fuel efficiency and environmental consciousness. This generation, identified by the chassis code XW20, features a 1.5L Atkinson cycle engine paired with an electric motor, delivering impressive combined horsepower and torque. The vehicle's design prioritizes aerodynamic efficiency and offers a spacious interior, making it a practical choice for daily commuting and long-distance travel. The commitment to engineering quality and reliability is evident in the Prius's advanced powertrain and robust construction, solidifying its position as a leader in sustainable automotive technology. This comprehensive Service and Repair Manual provides detailed instructions for maintaining and repairing the 2004-2009 Prius. With over 5000 pages of content, it covers all aspects of the vehicle, from routine maintenance schedules and fluid specifications to in-depth engine and hybrid system diagnostics and rebuilding procedures. Key areas include engine overhaul, the Hybrid Synergy Drive system, braking systems, suspension, transmission servicing, and the complete electrical system with detailed wiring diagrams. The manual is designed for both do-it-yourself enthusiasts and professional technicians, offering troubleshooting guides, torque specifications, and detailed procedures for components such as the timing chain and CV joints. Its searchable format and bookmarking ensure efficient access to critical information, empowering owners and mechanics to keep their Prius operating at peak performance and efficiency.
    🏷️ Basic Information
    Identification
    Make:
    Toyota
    Model:
    Prius
    Generation:
    2nd Generation (XW20)
    Production Years Covered:
    2004-2009
    Chassis Code:
    XW20
    👋 Introduction
    Market Position
    Target Audience:
    Do-it-yourself enthusiasts and professional mechanics seeking comprehensive repair and maintenance information for the 2004-2009 Toyota Prius.
    Competitive Analysis
    Value Proposition:
    Offers an inexpensive way to maintain and repair the vehicle, saving significant costs compared to dealership services.
    Key Features
    Unique Selling Points:
    Instant download, extensive detail with hundreds of photos and illustrations, detailed diagrams, wiring schematics, and troubleshooting guides.
    Ease Of Use:
    Searchable PDF format and bookmarks facilitate quick access to specific information.
    📋 Manual Details
    Coverage Areas
    Coverage Scope:
    Complete service and repair for all models and engines within the 2004-2009 Toyota Prius range.
    Page Count
    Total Pages:
    5000+
    Manual Type
    Type:
    Service and Repair Manual
    Language
    Language:
    English
    Format
    File Format:
    PDF
    📖 Manual Coverage
    Systems Covered
    Engine:
    Engine overhaul, rebuilding, performance tuning, troubleshooting, and diagnostics.
    Hybrid System:
    Comprehensive coverage of the Hybrid Synergy Drive system, including battery management, electric motor, and power control unit diagnostics and repair.
    Brakes:
    Brake servicing, hydraulic systems, ABS, and electronic brake-force distribution (EBD) procedures and specifications.
    Suspension:
    Front and rear suspension systems, including alignment procedures and specifications, shock absorber/strut replacement, and control arm servicing.
    Transmission:
    Removal, installation, and in-car servicing of the continuously variable transmission (CVT), including fluid specifications and torque converter procedures.
    Electrical System:
    Complete wiring diagrams, electrical component testing, diagnostic trouble trees, and troubleshooting for all vehicle circuits.
    Climate Control:
    Air conditioning service, refrigerant capacities, component diagnosis, and repair procedures.
    Body And Chassis:
    Sunroof operation and repair, interior trim removal, exterior panel servicing, and basic bodywork procedures.
    Procedures Included
    Maintenance:
    Factory recommended maintenance schedules and charts, fluid replacement procedures, filter changes, and tune-up specifications.
    Diagnostics:
    Extensive diagnostic procedures, including computer diagnostic trouble codes, diagnostic trouble tree charts, and symptom-based troubleshooting.
    Rebuilding:
    Detailed step-by-step instructions for engine overhaul and rebuilding, transmission servicing, and component refurbishment.
    Timing Belt:
    Specific procedures for timing belt replacement, including tensioner and pulley servicing, and critical timing mark alignment.
    Torque Specifications:
    Complete torque specifications for all critical fasteners, ensuring proper assembly and preventing component damage.
    Cv Joints:
    U-joint and CV-joint service procedures, including boot replacement and assembly guidelines.
    Technical Depth
    Depth:
    Covers all aspects from basic do-it-yourself maintenance to advanced diagnostics and complete vehicle rebuilding, suitable for both novice and professional technicians.
    📊 Manual Specifications
    File Format
    Compatibility:
    Compatible with all versions of Windows, Mac, Linux OS, iPhone, iPad, and Android devices.
    Requirements:
    Adobe PDF Reader and WinZip (or equivalent decompression software) are required.
    Print Quality
    Quality Description:
    High-quality, complete, and intact manual with no missing or corrupt pages. Bookmarked and searchable for easy navigation.
    Printing Capability:
    Printable pages allow for on-demand printing of specific sections or the entire manual.
    Binding Type
    Type:
    Digital Download (PDF)
    Paper Type
    N A:
    N/A (Digital Format)
    ⚙️ Engine Specifications
    Primary Engine
    Engine Code:
    1NZ-FXE
    Engine Type:
    1.5L (1497cc) DOHC 16-valve Inline-4 Atkinson Cycle Hybrid Engine
    Performance
    Combined Horsepower:
    Approx. 110 hp (82 kW) @ 5000 rpm (combined system output with electric motor)
    Combined Torque:
    Approx. 153 lb-ft (208 Nm) @ 4000 rpm (combined system torque)
    Fuel System
    Fuel Delivery:
    Electronic Fuel Injection (EFI)
    Fuel Type:
    Unleaded Gasoline
    Engine Management
    Engine Control Unit:
    Engine Control Module (ECM) / Hybrid Control Computer (HCC)
    Timing
    Timing Mechanism:
    Timing Chain (note: some sources may incorrectly refer to a belt; the 1NZ-FXE uses a chain)
    🔧 Transmission
    Standard
    Type:
    Electronically Controlled Continuously Variable Transmission (ECVT) with Integrated Electric Motor (MG2)
    Optional
    N A:
    N/A
    Features
    Driving Modes:
    EV Mode, Power Mode, Eco Mode
    Fluid Requirements
    Transmission Fluid Type:
    Toyota Genuine ATF WS (World Standard)
    Transmission Fluid Capacity:
    Approx. 4.2 Liters (4.4 US Quarts) for initial fill. Consult manual for exact capacity during service.
    📐 Dimensions
    Exterior
    Length:
    Approx. 174.6 inches (4435 mm)
    Width:
    Approx. 67.7 inches (1720 mm)
    Height:
    Approx. 57.3 inches (1455 mm)
    Wheelbase:
    Approx. 106.3 inches (2700 mm)
    Weights
    Curb Weight:
    Approx. 3010 - 3070 lbs (1365 - 1393 kg), varies by trim level
    🛡️ Safety Features
    Ratings
    NHTSA Front Impact:
    5 Stars (for models tested)
    IIHS Side Impact:
    Good (for models tested)
    Active Features
    Braking System:
    Regenerative braking system, Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Brake Assist (BA)
    Passive Features
    Airbags:
    Front airbags, front side-impact airbags, front and rear side curtain airbags (standard on most trims).
    Seatbelts:
    Three-point seatbelts with pretensioners and force limiters for all seating positions.
    💡 Technology Features
    Infotainment
    Display System:
    Touchscreen display for climate control, audio, and vehicle information. Optional navigation system available.
    Driver Assistance
    Cruise Control:
    Standard cruise control, optional Dynamic Radar Cruise Control (DRCC) on some higher trims.
    Connectivity
    Audio Inputs:
    AM/FM/CD player, optional auxiliary input jack.
    Hybrid Tech Features
    Regenerative Braking:
    Captures kinetic energy during deceleration to recharge the hybrid battery.
    Power Split Device:
    Manages power distribution between the gasoline engine and electric motors for optimal efficiency.
    🔧 Maintenance
    Service Intervals
    Oil Change Interval:
    Every 5,000 miles (8,000 km) or 6 months, whichever comes first, using synthetic oil. Check manual for specific conditions.
    Engine Air Filter:
    Replace every 30,000 miles (48,000 km) or as needed based on inspection.
    Cabin Air Filter:
    Replace every 10,000 miles (16,000 km) or 12 months.
    Coolant Replacement:
    Toyota Super Long Life Coolant (SLLC) for hybrid system and engine. Initial replacement at 100,000 miles (160,000 km), then every 50,000 miles (80,000 km).
    Fluid Specifications
    Engine Oil Type:
    SAE 0W-20 Synthetic (preferred)
    Engine Oil Capacity:
    Approx. 4.0 US Quarts (3.8 Liters) with filter change.
    Known Issues
    Hybrid Battery Degradation:
    As with most hybrid vehicles of this era, eventual degradation of the high-voltage battery pack is a common concern, though often addressed under warranty or with replacement.
    Water Pump Leaks:
    Occasional reports of water pump leaks, particularly the electric water pump for the hybrid system.
    Catalytic Converter Issues:
    Rare instances of catalytic converter failure, often due to other underlying engine issues.
    📚 Vehicle History
    Brand Heritage
    Toyota Hybrid Legacy:
    Toyota has been a pioneer in hybrid technology, with the Prius being the flagship model that popularized hybrid vehicles globally.
    Model Evolution
    Generation Overview:
    The 2nd generation Prius (XW20) marked a significant redesign, offering a more spacious interior, improved aerodynamics, and enhanced hybrid system efficiency.
    Production
    Manufacturing Location:
    Primarily Japan, with some assembly in other global locations.
    🏆 Awards & Recognition
    Recognitions
    Environmental Awards:
    Consistently recognized for its fuel efficiency and reduced emissions, contributing to its reputation as an environmentally friendly vehicle.
    Ratings
    Fuel Economy:
    EPA estimated MPG: 55 City / 50 Highway / 52 Combined (varies slightly by model year and specific configuration).
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