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Toyota Prius Service Repair Manual 2004-2009

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🏷️ 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...
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类型: Car
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斯库: 104940
Toyota Prius Service Repair Manual 2004-2009Toyota Prius Service Repair Manual 2004-2009Toyota Prius Service Repair Manual 2004-2009Toyota Prius Service Repair Manual 2004-2009
🏷️ 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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