Repair / Service Manuals ( which?)

I'm seriously getting into repair and service of the Gen2 family of Prius. I already have a set of Toyota Prius "Classic" manuals and although the give me a general understanding of what might expect to find in the Gen2 set, I seem to sense that one set might not truly cover the 2004 thru 2009. The cost of these manual are up to several hundred dollars on ebay and seem to be year specific.
BTW: I have downloaded the Electrical Vol. 3 from the file section and won't need to purchase that, if I don't mind printing out ~300+ pages.

I have always prefered the Bentley manuals over the Haynes or Chilton and have purchased a Bentley and will see what kind of coverage it has.

Also, while searching for Gen2 manuals on ebay, I found 2000 Toyota Prius Collision Damage Body Shop Service Manual (RX639) manual offered. I haven't seen what detail there is in this manual but wonder if a similar manual was offered for the Gen2 and if anybody has one?? Most of my work is Collision Damage. I have noticed the body structure is substantially different (heavier) in the Gen2 than the earlier models of that period. The internal tubular "roll-cage" structure accounts for a better roll-over performance in the Gen2. Just my observation, FWIW.

Steve

 

Sounds good, until I get to the cost. Not in my network. I might keep it in mind for an Hourly use for special questions searches.

Thanks

 

I got my Bentley manual for the Gen2 today. It's a nicely bound single volume of about 1000 pages (hard to say, since it is broken into 15 sections).

This is a Prius specific book with good introduction to the Prius Hybrid Systems. Although some photos and illustrations are credited and from the Toyota manuals and literature, many more are from Bentley Puplishers and some "branded". Right now, it would be difficult for me to compare this manual with the Toyota 3 vol. set since some of Bentleys discriptions and illustrations are reprinted (with permission statements). Also, I only have the Gen1 (classic) manual set to compare with. I like Bentley's electrial diagrams since they are better that the "block illustration" drawings in the Toyota Electrical that I have from the file section of this forum.
Good diagnostics section but is dedicated to the Techstream scan tool/Mastertech hand held tester. With reference to "AutoEnginuity and others" which are CAN compatable.

They do gave a very good section on the HV battery and is the Saftey Section.

I think it is a keeper for my shop. However. like all manuals I've seen since early '90 model years, no real coverage for major engine or transaxle tear down and rebuild procedures or parts diagrams. From what I have seen of the Toyota Prius manual, these couldn't be what the dealers mechanics work from. Since they lack this type of info as well. Or maybe that explains why seem to lack understanding and knowledge. (Some still think the Pruis engine won't start because the isa problem with battery is dead or "there is a problem with the starter". Sorry, a different Rante!)

Not sure where we are to go for engine rebuild info if not in the Toyota manual. The Bently manual has 51 pages in the Engine section. The too many cover removal of covers and interferiences "courtesy of Toyota.....". Some detail on the top end, cam and timing gear/chain removal and timing. Nothing below that. I haven't found anything on head bolt torque or sequence, so I will conclude that " Valve repair work is beyond the scope of this manual and the home mechanic should leave this work for the proffessional mechanic.." not stated in this Bentley manual but inferred by the absense of information. I once saw that statement in a Datsun service manual sold at the dealer parts counter circa 1974.

As I under stand it, the basic mechanical portion of this 1.5L engine is a Sion. That being true or not I'm ready to be corrected. If true then maybe there is an opportunity to find parts and rebuild specs. from that corner of the DIY repair world. (Just helped a friend with his '93 1.5L Tercel. Looked similar, hmm! Yah! I know the Prius have variable valve timing and Bentley does a reasonable job of explaining that point, however, nothing on trouble shooting a problem in that area. About all the deal could recommend is replace the engine! Speaking of replacing the engine, I don't see even that procedure in any of the manuals I have looked at. Maybe I have miss this someplace.

Steve (still learning at 75)

 

I'm not suggesting replacing with other Toyota engines and recognize the need for the unique design of the existing engine. I'm already seeing offers of remanufactured engines online so someone is already rebuilding them. I rebuild import engines already and the valve work, cylinder boring, etc. aren't going to be that much different. So once you locat an aftermarket source for parts, you are still left with a need for clearance and the torque and sequence. I'm sure the dealer has that and therefore Toyota should have provided it in the Manuals they offer, even if that phase of repair is in an additional volume.

Then there is the CVT/MG tranny/transaxle. We should all recognize by now that the Gen1 (classic) and Gen2 have a chain drive. I know we all like to think that these cars will run for ever and hear of those that reach 300-400k mile. My 2002 Classic has 279,000 and runs amazingly quite, however I have a GenII that served as a Yellow Cab, for the last part of it's 286,000 miles and let me tell you, I know "chain noise" when I hear it. I haven't even driven it on the road yet but know I will have to replace the CVT or replace the chain. Now I can get a used CVT on ebay for about $600 to $800 but looking at the cut-away drawings, it doesn't appear to be that big a deal to replace the chain, provided a relacement is available, dealer or aftermarket. Just need a little guidance. I suppose one could pay for a couple hours on Toyota Tech Support.

Steve

 

I now stand corrected!
I just recieved my order of Toyota Repair Manuals. Vol. 1-1, 1-2, 1-3 and Vol 2-1, 2-2, 2-3. I didn't order the Vol. 3 Electrical since I have that already in PDF.
These 6 books have a lot more info than I saw in the (borrowed) Prius 2001 manual set. And I would also say they have more indepth and detailed information than the Bentley manual.

As I stated in my previous post. my concern and interest in tear down, inspection and repair of the engine and CVT transaxle. This Toyota manual covers this well, except it seems to lack some inspection criteria on the CVT and MG components. It could be there and I have just missed it. The engine rebuild is well covered as is the procedures for removal of the engine/transaxle.

Of course, trouble shooting is in the "Flow Step" format and something I am not very patient with but I suppose, in the end, serves the purpose. Explaination of component purpose and function is very lite in details but again serves the tech purpose.

Oh! How much?? Well the Bentley manual cost me about $69. The Toyota volumes (6 books) go for anywhere from $97 to several hundred on ebay. In my search I found a new set of Volume 2 for $45 and orded them. What they sent me was both Volume 1 and 2 (the whole 6 book set) for the $45. I am well pleased, of course.

Steve