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Toyota Warnings and Cautions Please read and follow these warnings when working

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Please read and follow these warnings when working
Posted: Jun 24, 2008 2:09 PM
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- Be sure that the hybrid system is OFF (READY indicator not illuminated) before beginning any repair procedure. Remove the ignition key or Smart Key (if equipped) from - the vehicle. Store Smart Key in a safe place at least 15 feet away from the vehicle. For added safety, switch the Smart Key function (if equipped) OFF by depressing the cancel switch under the steering column.

- The Prius hybrid system has circuits with voltages as high as 500 volts. Voltages over 60 volts DC and 25 volts (rms) AC are a shock hazard. Wear lineman's gloves when removing the service plug, and whenever high voltage may be present.

- Wait at least five minutes after removing the service plug to allow high voltage capacitors to discharge before servicing the vehicle.

- After removing the service plug, test high voltage components for residual voltage to ensure that high voltage has dissipated before beginning work. Wear lineman's gloves until you are sure that high voltage is not present.

- Disconnect the 12-volt auxiliary battery negative (-) terminal whenever you work on the fuel system or the electrical system.

- If any procedure, tightening torque, wear limit, specification or data presented in this manual does not appear to be appropriate for a specific application, contact the publisher or the vehicle manufacturer for clarification before using the information in question.

- Do not reuse worn or deformed fasteners. Many fasteners are designed to be used only once and become unreliable and may fail when used a second time. This includes, but is not limited to, nuts, bolts, washers, self-locking nuts or bolts, snap rings and cotter pins. Replace these fasteners with new parts.

- When towing a Prius, do not allow the front wheels to rotate. Tow the vehicle with the front wheels on a towing dolly or transport on a flatbed. The front wheels are directly connected to motor / generator 2 (MG2). When the front wheels are turning MG2 also turns. This may generate high voltage and create a shock hazard, and also cause damage to the inverter or high voltage battery.

- Do not work under a lifted car unless it is solidly supported on stands designed for the purpose. Do not support a car on cinder blocks, hollow tiles, bricks, or other props that may crumble under continuous load. Do not work under a car that is supported solely by a jack. Do not work under the car while the engine is running.

- If you are going to work under a car on the ground, make sure that the ground is level. Block the wheels to keep the car from rolling. Disconnect the 12-volt auxiliary battery negative (-) terminal to prevent anyone from starting the car while you are under it.

- Place jack stands only at locations specified by the manufacturer. The vehicle lifting jack supplied with the vehicle is intended for tire changes only. Use a heavy duty floor jack to lift vehicle before installing jack stands.

- Do not run the engine unless the work area is well ventilated. Carbon monoxide kills.

- Remove rings, bracelets and other jewelry so that they cannot cause electrical shorts, get caught in running machinery, or be crushed by heavy parts.

- Tie long hair behind your head. Do not wear a necktie or scarf, loose clothing or a necklace when you work near machine tools or running engine. If your hair, clothing, or jewelry were to get caught in the machinery, severe injury could result.

- Do not attempt to work on your car if you do not feel well. You increase the danger of injury to yourself and others if you are tired, upset or have taken medication or any other substance that may keep you from being fully alert.

- Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the car. Make sure that the bulb is enclosed in a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel, vapors or oil.

- When draining fuel, oil, coolant or brake fluid, collect in suitable containers. Do not use food or beverage containers that might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at once, but do not store oily rags, which can ignite and burn spontaneously.

- Greases, lubricants and other automotive chemicals contain toxic substances, many of which are absorbed directly through the skin. Read the manufacturer's instructions and warnings carefully. Use hand and eye protection. Avoid prolonged direct skin contact.

- Many solvents used for parts cleaning contain hazardous, toxic chemicals, and are highly flammable, especially in aerosol form. Use with extreme care in well ventilated areas. Do not smoke. Do not use these products near sources of heat, sparks or flame. Read label warnings.

- Observe good workshop practices. Wear goggles when you operate machine tools or work with battery acid. Wear gloves or other protective clothing whenever the job requires working with harmful substances.

- Do not remove engine radiator pressure cap when engine is hot. Hot coolant may spray under pressure and cause severe burns.

- Coolant stored in the coolant heat storage tank can remain hot (as high as 176°F) for as long as 3 days. A malfunction may cause the surface of the coolant heat storage tank to become very hot. Use extreme caution when working around the coolant heat storage tank.

- Use extreme care when draining engine coolant. Even when the engine is cold, the coolant heat storage tank maintains coolant at high temperature. Hot engine coolant can cause severe burns.

- Allow transaxle to cool before checking or draining transaxle fluid. Hot transaxle fluid can cause severe burns.

- Bleeding the brake hydraulic system or changing brake fluid without using the Toyota hand-held tester or equivalent tool is not recommended. Air may remain trapped in lines or components, creating a hazardous condition.

- Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.

- Use and wear appropriate safety equipment while performing services and repairs.

- Lead-acid batteries give off explosive hydrogen gas during charging. Keep sparks, lighted matches and open flames away from the top of the battery. If escaping hydrogen gas is ignited, the flame may travel into the cells and cause the battery to explode.

- Battery acid (electrolyte) in the 12-volt auxiliary lead-acid battery can cause severe burns. Flush contact area with water, then seek medical attention.

- Replace the 12-volt auxiliary battery with a new battery of similar type. Do not substitute a conventional flooded-cell lead-acid battery.

- Nickel metal hydride battery cells in the high voltage battery pack contain a very caustic alkaline electrolyte which can cause severe burns. Seek medical attention immediately when exposed.

- The air-conditioning system is filled with chemical refrigerant which is hazardous. Make sure the system is serviced only by a trained technician using approved refrigerant recovery / recycling equipment, trained in related safety precautions, and familiar with regulations governing the discharging and disposal of automotive chemical refrigerants.

- Do not expose any part of the A/C system to high temperatures such as an open flame. Excessive heat increases system pressure and may cause the system to burst.

- Friction materials (such as brake pads and shoes) contain asbestos fibers or other similar materials. Do not create dust by grinding, sanding, or by cleaning with compressed air. Avoid breathing dust. Breathing any friction material dust can cause serious diseases and may result in death.

- Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the tire from the rim before attempting any repair.

- Aerosol tire inflators are not recommended for use on vehicles with tire pressure monitoring systems.

- Vehicles covered by this manual are equipped with a supplemental restraint system (SRS) that automatically deploys airbags and pyrotechnic seat belt tensioners in case of a frontal or side impact. These are explosive devices. Handled improperly or without adequate safeguards, they can be accidentally activated and can cause serious injury.

- The ignition system produces high voltages that can be fatal. Avoid contact with exposed terminals and use extreme care when working on a vehicle with the engine running or the ignition in READY mode.

- Aerosol cleaners and solvents may contain hazardous or deadly vapors and are highly flammable. Use only in a well ventilated area. Do not use on hot surfaces (engines, brakes, etc.).


- If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, leave such repairs to an authorized Toyota dealer or other qualified shop.

- Toyota is constantly improving its cars and sometimes these changes, both in parts and specifications, are made applicable to earlier models. Any part numbers listed in this manual are for reference only. Check with your authorized Toyota dealer parts department for the latest information.

- Before starting a job, be sure that you have the necessary tools and parts on hand. Read all the instructions thoroughly, and do not attempt shortcuts. Use tools appropriate to the work and use only replacement parts meeting Toyota specifications.

- Use pneumatic and electric tools only to loosen threaded parts and fasteners. Do not use these tools to tighten fasteners, especially on light alloy parts. Use a torque wrench to tighten fasteners to the tightening torque specification listed.

- Be mindful of the environment and ecology. Before you drain engine or transaxle lubricants, learn the proper way to dispose of the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond or lake. Dispose of waste in accordance with federal, state and local laws.

- The control module for the anti-lock brake system (ABS) cannot withstand temperatures from a paint-drying booth or a heat lamp in excess of 203°F (95°C). Do not subject to temperatures in excess of 185°F (85°C) for more than two hours.

- Before doing any electrical welding on cars equipped with ABS, disconnect the 12-volt auxiliary battery negative (-) terminal (ground strap) and the ABS control module connector.

- Be sure that the hybrid system is OFF (READY indicator not illuminated) before disconnecting the 12-volt auxiliary battery.

- Do not depress the POWER button when the Service Plug is removed from the vehicle. Damage to electronic control units (ECUs) may occur.

- Do not charge the 12-volt auxiliary battery with a fast charger. This battery is an absorbed glass mat (AGM) type battery, and must be charged at a low rate not to exceed 3.5 amps. Disconnect the battery from the vehicle before charging.

- Connect and disconnect a battery charger only with the battery charger switched OFF.

- Do not drive a Prius when in inspection mode. Transaxle damage may occur.

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