O2 sensor TOYOTA PRIUS 2001 Service Repair Manual

A13908
A13938
A13909
I18009
A13932
EM±54
± ENGINE MECHANICALENGINE UNIT
2001 PRIUS (RM778U)
13. DISCONNECT SHIFT LEVER CABLE
14. REMOVE BRAKE RESERVOIR TANK
(a) Disconnect the brake fluid level sensor connector.
(b) Remove the 2 bolts and remove the reservoir tank and
suspend it.
15. DISCONNECT ENGINE WIRE FROM CABIN
(a) Remove the ECM (See page SF±63).
(b) Disconnect the grommet from the cowl panel, and pull out
the engine wire.
16. REMOVE J/B NO. 1 FROM RH FENDER APRON
17. DISCONNECT FUEL TUBE
Disconnect the fuel tube from the fuel pump.
18. REMOVE DRIVE BELT
19. REMOVE ENGINE UNDER COVERS
20. REMOVE A/C COMPRESSER
(a) Disconnect the A/C compresser connector.
(b) Remove the 4 bolts and disconnect the A/C compresser
from the engine.
HINT:
Suspend the A/C compresser securely.
21. DISCONNECT INTERMEDIATE EXTENSION FROM
STEERING ASSEMBLY (See page SR±6)
22. REMOVE EXHAUST PIPE
(a) Disconnect the heated oxygen sensor from the exhaust
pipe.
(b) Remove the 2 springs and 3 bolts.
(c) Disconnect the 2 O±rings, and remove the exhaust pipe
and 2 gaskets.

A13939
I18009
A13909
A13938
EM±60
± ENGINE MECHANICALENGINE UNIT
2001 PRIUS (RM778U)
12. INSTALL EXHAUST PIPE
(a) Install the 2 gaskets to the exhaust pipe and connect the
2 O±rings.
(b) Install the 2 springs and 3 bolts.
Torque:
Front exhaust pipe: 62 N´m (630 kgf´cm, 46 ft´lbf)
Tailpipe: 32 N´m (326 kgf´cm, 24 ft´lbf)
(c) Connect the hose to the actuator.
(d) Connect the heated oxygen sensor.
13. INSTALL A/C COMPRESSER
(a) Connect the A/C compresser to the engine with the 4
bolts.
Torque: 25 N´m (255 kgf´cm, 18 ft´lbf)
(b) Connect the A/C compresser connector.
14. CONNECT INTERMEDIATE EXTENSION STEERING
ASSEMBLY (See page SR±14)
15. INSTALL DRIVE BELT (See page SA±23)
16. CONNECT FUEL TUBE
17. INSTALL J/B NO. 1 TO RH FENDER APRON
18. CONNECT ENGINE WIRE TO CABIN
(a) Pull in the engine wire to the cowk panel and connect the
grommet.
(b) Connect the ECM connectors.
(c) Install the ECM (See page SF±63).
19. INSTALL BRAKE RESERVOIR TANK
(a) Install the reservoir tank with the 2 bolts.
(b) Connect the brake fluid level sensor connector.
20. CONNECT SHIFT LEVER CABLE TO TRANSAXLE
21. CONNECT HEATER HOSE TO CYLINDER BLOCK
22. CONNECT 2 RADIATOR HOSES TO RADIATOR
23. INSTALL ENGINE COOLANT RESERVOIR TANK
24. INSTALL AIR INLET

A13943
A13907
± ENGINE MECHANICALENGINE UNIT
EM±61
2001 PRIUS (RM778U)
25. CONNECT CONNECTORS, CLAMPS AND HOSES
(a) Connect the Ground strap from LH fender apron.
(b) Connect the Ground strap from RH fender apron.
(c) Connect the VSV hose for purge line.
(d) Connect the VSV connector for purge line.
(e) Connect the 2 power steering connectors.
(f) Connect the Heated oxygen sensor connector.
(g) Connect the Engine wire clamps.
26. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner assembly with the 2 bolts.
(b) Tighten the 2 hose clamps.
(c) Connect the EVAP hose to the air cleaner case.
(d) Connect the MAF meter connector.
27. INSTALL HEATER UNIT WATER PUMP
(See page AC±55)
28. INSTALL CONVERTER AND INVERTER ASSEMBLY
(See page HV±22)
29. INSTALL OUTER FR COWL TOP PANEL ASSEMBLY
(See page BO±35)
30. FILL WITH ENGINE COOLANT
31. FILL WITH HV COOLANT
32. INSTALL ENGINE UNDER COVERS
33. CONNECT BATTERY NEGATIVE (±) TERMINAL AND
HV BATTERY SERVICE PLUG (See page HV±1)
34. ROAD TEST VEHICLE
Check for abnormal noiss, shock slippage, correct shift points
and smooth operation.
35. RECHECK ENGINE COOLANT AND HV TRANSAXLE
COOLANT

EM17B±02
A11250
Water Bypass Pipe
Knock Sensor
Thermostat
Water Inlet Engine Coolant
Drain Union

N´m(kgf´cm, ft´lbf) : Specified torque
Non±reusable part

Precoated part
Gasket


GasketOil Pressure
Switch
9.0 (90, 80 in.´lbf)
9.0 (90, 80 in.´lbf)
9.0 (90. 80 in.´lbf)
9.0 (90, 80 in.´lbf)
EM±62
± ENGINE MECHANICALCYLINDER BLOCK
1178 Author: Date:
2001 PRIUS (RM778U)
CYLINDER BLOCK
COMPONENTS

EM17C±04
A10451
A11268
A11269
A14342
EM±64
± ENGINE MECHANICALCYLINDER BLOCK
2001 PRIUS (RM778U)
DISASSEMBLY
1. INSTALL ENGINE TO ENGINE STAND FOR
DISASSEMBLY
2. REMOVE TIMING CHAIN (See page EM±15)
3. REMOVE CYLINDER HEAD
(See page EM±29)
4. REMOVE ENGINE WIRE
5. REMOVE WATER BYPASS PIPE
Remove the 2 nuts, bolt and water bypass pipe.
6. REMOVE THERMOSTAT
(See page CO±10)
7. REMOVE KNOCK SENSOR (See page SF±56)
8. REMOVE OIL PRESSURE SWITCH
(See page LU±1)
9. REMOVE ENGINE COOLANT DRAIN UNION
10. REMOVE OIL FILTER
(See page LU±3)
11. REMOVE OIL FILTER UNION
Using a 12 mm hexagon wrench, remove the oil filter union.
12. REMOVE OIL PAN NO. 2
(a) Remove the 9 bolts and 2 nuts.
(b) Insert the blade of SST between the oil pan No. 1 and oil
pan No. 2, and cut off applied sealer and remove the oil
pan.
SST 09032±00100
NOTICE:

Be careful not to the damage the oil pan contact sur-
face of the oil pan No. 1.

Be careful not to damage the oil pan No. 2 flange.
13. REMOVE OIL STRAINER
Remove the bolt and 2 nuts, oil strainer and gasket.

P12477
Adhesive
A10451
± ENGINE MECHANICALCYLINDER BLOCK
EM±83
2001 PRIUS (RM778U)
18. INSTALL ENGINE COOLANT DRAIN UNION
(a) Apply adhesive to 2 or 3 threads.
Adhesive:
Part No. 08833±00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Install the drain union.
Torque: 35 N´m (350 kgf´cm, 25 ft´lbf)
HINT:
After applying the specified torque, rotate the drain union clock-
wise until its drain port is facing downward.
19. INSTALL KNOCK SENSOR
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
20. INSTALL OIL PRESSURE SWITCH
(See page LU±1)
21. INSTALL THERMOSTAT
(See page CO±12)
22. INSTALL WATER BYPASS PIPE
Torque: 9.0 N´m (92 kgf´cm, 80 in.´lbf)
23. INSTALL ENGINE WIRE
24. INSTALL CYLINDER HEAD
(See page EM±45)
25. INSTALL TIMING SPROCKETS AND TIMING CHAIN
(See page EM±21)
26. REMOVE ENGINE STAND

EC0HT±01
B11797
Charcoal Canister VSV for EVAP
Heated Oxygen Sensor
(Bank 1 Sensor 1)
Heated Oxygen Sensor
(Bank 1 Sensor 2) Fuel Tank
Air Cleaner
Throttle Valve
Pressure Sensor
for HCAC
Check
Valve VSV for HCAC
Actuator for HCAC
Refer to next page
± EMISSION CONTROLPARTS LAYOUT AND SCHEMATIC DRAWING
EC±3
2001 PRIUS (RM778U)
DRAWING

B11798
Air Cleaner
Throttle Valve
VSV for
EVAP
Purge Line
VSV for Purge Flow
Switching Valve
Charcoal
Canister
EVAP Line
Fuel Tank Vapor Pressure
Sensor Trap Filter Fresh Air
Valve
Canister Closed
Valve Filler Pipe
EC±4
± EMISSION CONTROLPARTS LAYOUT AND SCHEMATIC DRAWING
2001 PRIUS (RM778U)

SF1KN±01
± SFISFI SYSTEM
SF±1
1215 Author: Date:
2001 PRIUS (RM778U)
SFI SYSTEM
PRECAUTION
1. BEFORE WORKING ON THE FUEL SYSTEM , DIS-
CONNECT THE NEGATIVE (±) TERMINAL CABLE
FROM THE BATTERY AND HV BATTERY SERVICE
PLUG
HINT:
Any diagnostic trouble code retained by the computer will be
erased when the negative (±) terminal cable is removed from
the battery. Therefore, if necessary, read the diagnosis before
removing the negative (±) terminal cable from the battery.
2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME
WHEN WORKING ON THE FUEL SYSTEM
3. KEEP GASOLINE AWAY FROM RUBBER OR
LEATHER PARTS
4. MAINTENANCE PRECAUTIONS
(a) In event of engine misfire, these precautions should be
taken.
(1) Check proper connection to battery terminals, etc.
(2) After repair work, check that the ignition coil termi-
nals and all other ignition system lines are recon-
nected securely.
(3) When cleaning the engine compartment, be espe-
cially careful to protect the electrical system from
water.
(b) Precautions when handling oxygen sensor.
(1) Do not allow oxygen sensor to drop or hit against an
object.
(2) Do not allow the sensor to come into contact with
water.
If vehicle is Equipped with Mobile Radio System (HAM, CB,
etc.)
If the vehicle is equipped with a mobile communication system,
refer to the precaution in the IN section.
5. AIR INDUCTION SYSTEM
(a) Separation of the engine oil dipstick, oil filler cap, PCV
hose, etc. may cause the engine to run out of turn.
(b) Disconnection, looseness or cracks in the parts of the air
induction system between the throttle body and cylinder
head will allow air suction and cause the engine to run out
of turn.
6. ELECTRONIC CONTROL SYSTEM
(a) Before removing SFI wiring connectors, terminals, etc.,
first disconnect the power by either turning the ignition
switch to LOCK or disconnecting the negative (±) terminal
cable from the battery.
HINT:
Always check the diagnostic trouble code before disconnecting
the negative (±) terminal cable from the battery.

SF1KR±01
B11453
N´m (kgf´cm, ft´lbf)

Non±reusable part: Specified torque
Gasket
Fuel Tank Assembly
Tail Pipe
39 (398, 29)

Gasket
Front Exhaust Pipe
45 (459, 33)
39 (398, 29)
39 (398, 29)
Parking Brake Cable
62 (632, 46)
Vacuum Hose for HCAC Heated Oxygen Sensor
(Bank 1 Sensor 2)
± SFIFUEL TANK AND LINE
SF±17
2001 PRIUS (RM778U)
COMPONENTS