2004 Toyota Prius Service and Repair Manual

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Factory-Grade Data

2004 Toyota Prius service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you diagnose issues correctly, follow proven repair steps, and use wiring diagrams and system sections to track faults faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications, torque values, and reference data
  • Electrical diagnostics with full wiring diagrams
  • Coverage across major systems: engine, transmission/driveline, brakes, steering, suspension, HVAC, and more
  • Diagnostic trouble codes and troubleshooting flow
  • Maintenance schedules and fluid capacities

Trims covered

  • Base

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Maintenance & Lubrication
  • Specifications
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Diagnostic Trouble Codes
  • Technical Service Bulletins
  • Wiring Diagrams

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Vehicle Safety Data

2004 Toyota Prius Recalls & Complaints

NHTSA #04V55800022/11/2004Component: EXTERIOR LIGHTING:BRAKE LIGHTS:SWITCH

CERTAIN PASSENGER VEHICLES MAY BE EQUIPPED WITH AN IMPROPERLY DESIGNED BRAKE LIGHT SWITCH. A SILICON OXIDE BUILD-UP OCCURS ON THE CONTACTS INSIDE THE BRAKE LIGHT SWITCH, WHICH CAN MAKE IT INOPERABLE.

Consequence

IF THE SWITCH IS INOPERABLE, THE BRAKE LIGHTS WILL NOT ILLUMINATE AND CAN INCREASE THE RISK OF A CRA

Remedy

DEALERS WILL REPLACE THE BRAKE LIGHT SWITCH. THE RECALL BEGAN DURING DECEMBER 2004. OWNERS SHOULD

NHTSA #09V38800005/10/2009Component: VEHICLE SPEED CONTROL:ACCELERATOR PEDAL

TOYOTA IS RECALLING CERTAIN MODEL YEAR 2004-2010 PASSENGER VEHICLES. THE ACCELERATOR PEDAL CAN GET STUCK IN THE WIDE OPEN POSITION DUE TO ITS BEING TRAPPED BY AN UNSECURED OR INCOMPATIBLE DRIVER'S FL

Consequence

A STUCK OPEN ACCELERATOR PEDAL MAY RESULT IN VERY HIGH VEHICLE SPEEDS AND MAKE IT DIFFICULT TO STOP

Remedy

TOYOTA FILED AN AMENDED DEFECT REPORT ON NOVEMBER 25, 2009, STATING THAT DEALERS WILL MODIFY THE ACC

TSB #11029893

This bulletin includes basic procedures for performing a rescue charge on Ni-MH high voltage (HV) batteries. This bulletin should be used in conjunction with the applicable model and model year Repair Manual while performing a rescue charge

TSB #11029892

OBSOLETE NOTICE February 13, 2026: This bulletin is now obsolete. Please see T-SB-0009-26.

TSB #11012744

The condition known as acid rain is caused by airborne chemicals or particles in the atmosphere, which mix with rainwater, nighttime dew, or high humidity to form acidic compounds. If these contaminants settle and remain on a painted vehicl

TSB #11012743

To prevent brake rotor rust from forming during transportation and storage, wheel film will be used instead of a cardboard type of anti-rust cover. The purpose of the wheel film is to shield the disc brake rotor from weather elements and in

TSB #11012742

Acid rain results from rainwater or other airborne moisture that become acidic due to industrial chemical impurities in the atmosphere. If these acidic compounds settle on an exposed vehicle, especially the horizontal areas such as the hood

TSB #11012735

Toyota vehicles are currently protected with RapgardTM protective film designed to protect the horizontal painted surfaces. This material protects from acid rain, environmental fallout, and rail contamination. Follow the Removal Procedure i

TSB #11012727

Vehicles may occasionally be subjected to contamination by airborne iron particles shed from railroad tracks, train wheels, exposure to heavy machinery facilities, grinding, welding, etc. This type of contamination can be identified by the

TSB #11007445

The condition known as acid rain is caused by airborne chemicals or particles in the atmosphere, which mix with rainwater, nighttime dew, or high humidity to form acidic compounds. If these contaminants settle and remain on a painted vehicl

Showing the 8 most recent of 226 technical service bulletins on file with NHTSA.

20100311Component: SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITEDCrash reported4 injured

TL*THE CONTACT OWNS A 2004 TOYOTA PRIUS. THE CONTACT WAS DRIVING APPROXIMATELY 25 MPH ON A GRAVEL ROAD. PRESSURE WAS APPLIED TO THE BRAKE PEDAL AND THERE WAS NO POWER RESPONSE. THE VEHICLE FAILED TO S

20110218Component: SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITEDCrash reported3 injured

TL*THE CONTACT OWNS A 2004 TOYOTA PRIUS. WHILE DRIVING APPROXIMATELY 55 MPH THE VEHICLE ACCELERATED ON ITS OWN. THE VEHICLE CRASHED INTO A CONCRETE DIVIDER ON THE HIGHWAY. THE CONTACT STATED THAT THE

20110218Component: VEHICLE SPEED CONTROLCrash reported3 injured

TL*THE CONTACT OWNS A 2004 TOYOTA PRIUS. WHILE DRIVING APPROXIMATELY 55 MPH THE VEHICLE ACCELERATED ON ITS OWN. THE VEHICLE CRASHED INTO A CONCRETE DIVIDER ON THE HIGHWAY. THE CONTACT STATED THAT THE

20140422Component: AIR BAGSCrash reported2 injured

I WAS DRIVING DOWNHILL, CAME AROUND A BLIND CURVE AND CARS WERE BACKED UP REALLY HIGH ON THE STREET. I REAR-ENDED THE CAR THAT WAS AT A DEAD STOP IN FRONT OF ME AS I TURNED THE CORNER. MY CAR CRUNCHED

20111209Component: AIR BAGSCrash reported2 injured

2004 TOYOTA PRIUS FRONTAL IMPACT CRASH INTO REAR OF VEHICLE 2, 2002 HONDA CRV, ON TUESDAY NOVEMBER 22, 2011, 4:33PM EST. BUMPER IMPACT AT APPROX SPEED 25MPH IN CLEAR CONDITIONS TOTALED SUBJECT VEHICL

Showing the 5 most serious of 737 complaints filed with NHTSA.

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