TOYOTA PRIUS 2001 Service Repair Manual

MA00R±17
B08810
± MAINTENANCEENGINE
MA±5
58 Author: Date:
2001 PRIUS (RM778U)
ENGINE
INSPECTION
HINT:
Inspect these items when the engine is cold.
1. INSPECT DRIVE BELT
(See page CO±4)
2. REPLACE SPARK PLUGS
(See page IG±1)
3. INSPECT AIR FILTER
(a) Visually check that the air filter is not excessively dirty or
oily.
HINT:
Oiliness may indicate a stuck PCV valve.
If necessary, replace the air cleaner element.
(b) Clean the air filter with compressed air.
First blow from the inside thoroughly, then blow off the
outside of the element.
4. REPLACE AIR FILTER
Replace the air filter with a new one.
5. REPLACE ENGINE OIL AND OIL FILTER
(See page LU±3)
6. REPLACE ENGINE COOLANT
(See page CO±2)
7. INSPECT CHARCOAL CANISTER
(Se page EC±7)
8. REPLACE GASKET IN FUEL TANK CAP
(See page SF±19)
9. INSPECT FUEL LINES AND CONNECTIONS
(See page SF±19)
10. INSPECT EXHAUST PIPES AND MOUNTINGS
(See page EC±13)
11. ADJUST VALVE CLEARANCE
(See page EM±5)

S01304
MA02H±03
MA±6
± MAINTENANCEBRAKE
59 Author: Date:
2001 PRIUS (RM778U)
BRAKE
INSPECTION
1. INSPECT BRAKE LINE PIPES AND HOSES
HINT:
Check in a well lighted area. Check the entire circumference
and length of the brake hoses using a mirror as required. Turn
the front wheels fully right or left before checking the front brake.
(a) Check all brake lines and hoses for:

Damage

Wear

Deformation

Cracks

Corrosion

Leaks

Bends

Twists
(b) Check all clamps for tightness and connections for leak-
age.
(c) Check that the hoses and lines are clear of sharp edges,
moving parts and the exhaust system.
(d) Check that the lines installed in grommets pass through
the center of the grommets.
2. INSPECT FRONT BRAKE PADS AND DISCS
(See page BR±29 )
HINT:
If a squealing or scraping noise comes from the brake during,
check the pad wear indicator to see if it is contacting the disc
rotor. If so, the disc pad should be replaced.
3. INSPECT BRAKE LININGS AND DRUMS
(See page BR±35)

MA048±01
S01303
Dust Cover
± MAINTENANCECHASSIS
MA±7
60 Author: Date:
2001 PRIUS (RM778U)
CHASSIS
INSPECTION
1. INSPECT STEERING LINKAGE
(a) Check the steering wheel freeplay. (See page SR±3)
(b) Check the steering linkage for looseness or damage.
Check that:

Tie rod ends do not have excessive play.

Dust seals and boots are not damaged.

Boot clamps are not loose.
2. INSPECT SRS AIRBAG (See page RS±2)
3. INSPECT STEERING GEAR HOUSING OIL
Check the steering gear housing for oil leakage.
4. INSPECT DRIVE SHAFT BOOTS
Check the drive shaft boots for clamp looseness, leakage or
damage.
5. INSPECT BALL JOINTS AND DUST COVERS
(a) Inspect the ball joints for excessive looseness.

Jack up the front of the vehicle and place wooden
blocks with a height of 180 ± 200 mm (7.09 ± 7.87
in.) under the front tires.

Lower the jack until there is about half a load on the
front coil spring. Place stands under the vehicle for
safety.

Check that the front wheels are pointing straight
ahead, and block them with chocks.

Using a lever, pry up the end of the lower arm, and
check the amount of play.
Maximum ball joint vertical play: 0 mm (0 in.)
If there is play, replace the ball joint.
(b) Check the dust cover for damage.
6. CHECK TRANSAXLE OIL (FLUID)
Visually check the transaxle for oil (fluid) leakage.
If leakage is found, check for the cause and repair.
7. REPLACE TRANSAXLE OIL (FLUID)
Replace the transaxle oil (See page HT±26).

P21235
MA049±01
F12933
F12919
MA±8
± MAINTENANCEBODY
61 Author: Date:
2001 PRIUS (RM778U)
BODY
INSPECTION
1. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY
Tighten these parts:

Front seat mount bolts
Torque: 37 N´m (375 kgf´cm, 27 ft´lbf)

Front suspension member±to±body mounting bolts
Torque:
Bolt A: 113 N´m (1,150 kgf´cm, 83 ft´lbf)
Bolt B: 157 N´m (1,600 kgf´cm, 116 ft´lbf)

Rear suspension member±to±body mounting nuts
Torque: 90 N´m (918 kgf´cm, 66 ft´lbf)
2. FINAL INSPECTION
(a) Check the operation of the body parts:

Hood:
Auxiliary catch operate properly
Hood locks securely when closed

Front and rear doors:
Door lock operates properly
Doors close properly

Luggage compartment door:
Door lock operates properly

Seats:
Seat adjusts easily and locks securely in any posi-
tion
Front seat back locks securely in any position
Folding±down rear seat backs lock securely
(b) Road test:

Check the engine and chassis for abnormal noises.

Check that the vehicle does not wander or pull to
one side.

Check that the brake work properly and do not drag.
(c) Be sure to deliver a clean car. especially check:

Steering wheel

Shift lever knob

All switch knobs

Door handles

Seats

PP0E6±02
± PREPARATIONMAINTENANCE
PP±1
62 Author: Date:
2001 PRIUS (RM778U)
MAINTENANCE
EQUIPMENT
MirrorBrake hose
Torque wrench

PP3AW±01
PP±2
± PREPARATIONENGINE MECHANICAL
63 Author: Date:
2001 PRIUS (RM778U)
ENGINE MECHANICAL
SST (Special Service Tools)
09032±00100Oil Pan Seal Cutter
09201±01055Valve Guide Bushing Remover & Re
placer 5.5
09201±41020Valve Stem Oil Seal Replacer
09202±70020Valve Spring Compressor
(09202±00010)Attachment
09213±70010Crankshaft Pulley Holding Tool
09221±25026Piston Pin Remover & Replacer
(09221±00021)Body
(09221±00030)Spring
(09221±00141)Guide H
(09221±00150)Bushing ºDº
(09221±00190)Guide ºKº

± PREPARATIONENGINE MECHANICAL
PP±3
64 Author: Date:
2001 PRIUS (RM778U)
09222±30010Connecting Rod Bushing Remover
& Replacer
09223±15030Oil Seal & Bearing Replacer
09330±00021Companion Flange Holding Tool
09612±22011Tilt Handle Bearing Replacer
09950±50012Puller C Set
(09951±05010)Hanger 150
(09952±05010)Slide Arm
(09953±05020)Center Bolt 150
(09954±05020)Claw No.2
09950±70010Handle Set
(09951±07100)Handle 100
09301±00110Clutch Guide Tool

PP2FB±02
PP±4
± PREPARATIONENGINE MECHANICAL
2001 PRIUS (RM778U)
RECOMMENDED TOOLS
09090±04020Engine Sling Device
09200±00010Engine Adjust Kit .
09258±00030Hose Plug Set .

PP2FC±02
± PREPARATIONENGINE MECHANICAL
PP±5
2001 PRIUS (RM778U)
EQUIPMENT
Abrasive compoundValve
Caliper gauge
CO/HC meter
Compression gauge
Connecting rod aligner
Cylinder gauge
Dial indicator
Dye penetrant
Engine tune±up tester
Groove cleaning toolPiston ring groove
Heater
Magnetic finger
Micrometer
Pin hole grinderPiston pin hole of piston
Piston ring compressor
Piston ring expander
Plastigage
Precision straight edge
Press
Ridge reamerCylinder
Soft brush
Solvent
Spring testerValve spring
Steel squareValve spring
Thermometer
Torque wrench
Torx wrench socket setStud bolt
TOYOTA hand held tester or OBDII scan tool
Valve seat cutter
V±block
Vernier calipers
Wire brushValve

PP2FD±02
PP±6
± PREPARATIONENGINE MECHANICAL
2001 PRIUS (RM778U)
SSM (Special Service Materials)
08826±00080Seal Packing Black or equivalent
(FIPG)
08826±00100Seal Packing 1282B,
THREE BOND 1282B or equivalent
(FIPG)
08833±00070Adhesive 1324,
THREE BOND 1324 or equivalent