width TOYOTA PRIUS 2001 Service Repair Manual

ENGINE ± 1NZ-FXE ENGINE
171EG07
182EG07
Crankshaft Position
Sensor RotorOil HolePin
No.5 Journal
Balance Weight
No.1 Journal 48
4. Connecting Rod

The connecting rods are made of high-strength
material for weight reduction.

The connecting rod cap is held by bolts tight-
ened to plastic region.
5. Crankshaft

The crankshaft has 5 journals and 4 balance weights.

A crankshaft position sensor rotor has been pressed into the crankshaft to realize an integrated configura-
tion.

The surface roughness of the pins and journals have been improved for low-friction operation.

The bearing width has been reduced for low-friction operation.

CHASSIS ± P111 HYBRID TRANSAXLE
182CH21
Silent Chain
Final Gears
Differential ShaftCounter Gears Engine's Center Shaft 86
6. Reduction Unit
The reduction unit consists of the silent chain, counter gears and final gears.
A silent chain with a small pitch width has been adopted to ensure quiet operation, and the overall length has
been reduced in contrast to the gear-driven mechanism.
The counter gears and final gears teeth have been processed through high-precision housing and their tooth
flanks have been optimized to ensure extremely quiet operation.
The final gears have been optimally allocated to reduce the distance between the engine's center shaft and
the differential shaft, thus resulting in a transmission with a compact package.

DIFFERENTIAL UNIT
For the differential unit, a 2-pinion type that is similar to the differential unit of the conventional transaxle
has been adopted.

APPENDIX
5
10
15
20
25
30
35
40
45
50
55
60
65
70
Area
Item
Major Dimensions & Vehicle Weights Performance Engine Engine
Chassis
Electrical
192
MAJOR TECHNICAL SPECIFICATIONS
U.S.A. and CanadaBody Type4-Door SedanVehicle GradeÐModel CodeNHW11L-AEEEBANHW11L-AEEEBKLength mm (in.)4305 (169.5)u
OverallWidth mm (in.)1695 (66.7)uOverallHeight mm (in.)1465 (57.6)uWheel Base mm (in.)2550 (100.4)u
TreadFront mm (in.)1475 (58.1)uTreadRear mm (in.)1480 (58.3)u
Effective Head RoomFront mm (in.)985 (38.8)uEffective Head RoomRear mm (in.)942 (37.1)u
Effective Leg RoomFront mm (in.)1047 (41.2)uEffective Leg RoomRear mm (in.)899 (35.4)u
Shoulder RoomFront mm (in.)1342 (52.8)uShoulder RoomRear mm (in.)1325 (52.2)u
OverhangFront mm (in.)815 (32.1)uOverhangRear mm (in.)940 (37.0)uMin. Running Ground Clearance mm (in.)125 (4.9)uAngle of Approach degrees145uAngle of Departure degrees225uFront kg (lb)770 (1700)u
Curb WeightRear kg (lb)485 (1065)uCurb WeightTotal kg (lb)1255 (1765)uFront kg (lb)890 (1965)u
Gross Vehicle WeightRear kg (lb)750 (1650)uGross Vehicle WeightTotal kg (lb)1640 (3615)uFuel Tank Capacity
(US. gal., lmp.gal.)45* (11.9, 9.9)uLuggage Compartment Capacity m3 (cu.ft.)0.39 (137.7)uMax. Speed km/h (mph)160 (99.4)uMax. Cruising Speed km/h (mph)160 (99.4)u
Acceleration0 to 100 km/h sec.12.7uAcceleration0 to 400 m sec.19.0u1st Gear km/h (mph)ÐÐ
Max. Permissible2nd Gear km/h (mph)ÐÐMax. Permissible
Speed3rd Gear km/h (mph)ÐÐp
4th Gear km/h (mph)ÐÐ
Min. Turning RadiusWall to Wall m (ft.)10.2 (33.5)uMin. Turning Radius
(Outside Front)Curb to Curb m (ft.)9.4 (30.8)uEngine Type1NZ-FXEuValve Mechanism16-Valve, DOHCuBore y Stroke mm (in.)75.0 y 84.7 (2.95 y 3.33)uDisplacement cm3 (cu.in.)1497 (91.4)uCompression Ratio13.0uCarburetor TypeSFIuResearch Octane No. RON95uMax. Output (EEC) kW/rpm (HP@rpm)52/4500 (70@4500)uMax. Torque (EEC) N´m/rpm (lb-ft@rpm)111/4200 (82@4200)uBattery Capacity (5HR) Voltage & Amp. Hr.12 ± 28uAlternator Output WattsÐÐStarter Output kWÐÐClutch TypeÐÐTransaxle TypeP111uIn FirstÐÐIn SecondÐÐ
Transmission GearIn ThirdÐÐTransmission Gear
RatioIn FourthÐÐIn FifthÐÐIn ReverseÐÐCounter Gear RatioÐÐDifferential Gear Ratio (Final)3.905u
Brake TypeFrontVentilated DiscuBrake TypeRearL.T. DrumuParking Brake TypeL.T. DrumuBrake Booster Type and Size in.HydraulicuProportioning Valve TypeP-Valveu
Suspension TypeFrontMacPherson StrutuSuspension TypeRearTorsion Beanu
Stabilizer BarFrontSTDuStabilizer BarRearSTDuSteering Gear TypeRack and PinionuSteering Gear Ratio (Overall)16.4~18.3uPower Steering TypeElectric Motoru
*: EPA / CARB ORVR Test conditions

IN±48
± INTRODUCTIONTERMS
48 Author: Date:
2001 PRIUS (RM778U) H/B
Hatchback
H±FUSEHigh Current Fuse
HIHigh
HIDHigh Intensity Discharge (Head Lamp)
HSGHousing
HTHard Top
HVHybrid Vehicle
HWSHeated Windshield System
IACIdle Air Control
ICIntegrated circuit
IDIIndirect Diesel Injection
IFSIndependent Front Suspension
IGIgnition
IIAIntegrated Ignition Assembly
INIntake (Manifold, Valve)
INTIntermittent
I/PInstrument Panel
IRSIndependent Rear Suspension
J/BJunction Block
J/CJunction Connector
KDKick±Down
LANLocal Area Network
LBLiftback
LCDLiquid Crystal Display
LEDLight Emitting Diode
LHLeft±Hand
LHDLeft±Hand Drive
L/H/WLength, Height, Width
LLCLong±Life Coolant
LNGLiquified Natural Gas
LOLow
LPGLiquified Petroleum Gas
LSDLimited Slip Differential
LSP & PVLoad Sensing Proportioning And Bypass Valve
LSPVLoad Sensing Proportioning Valve
MAX.Maximum
MG1Motor Generator No. 1
MG2Motor Generator No. 2
MICMicrophone
MILMalfunction Indicator Lamp
MIN.Minimum
MPMultipurpose
MPXMultiplex Communication System
M/TManual Transmission
MTMount
MTGMounting

PP0T0±01
± PREPARATIONSUPPLEMENTAL RESTRAINT SYSTEM
PP±47
2001 PRIUS (RM778U)
EQUIPMENT
Torque wrench
Bolt: Length: 35 mm (1.38 in.) Pitch: 1.0 mm (0.039 in.)
Diam: 6.0 mm (0.236 in.)Airbag disposal
Tire Width: 185 mm (7.28 in.) Inner diam: 360 mm (14.17 in.)Airbag disposal
Tire with disc wheel Width: 185 mm (7.28 in.)
Inner diam: 360 mm (14.17 in.)Airbag disposal
Vinyl bagAirbag disposal

PP3B1±01
PP±54
± PREPARATIONBODY
2001 PRIUS (RM778U)
EQUIPMENT
Clip remover
Torque wrench
Hexagon wrench (6 mm)
Torx driver
Hog ring pliers
Hand riveter
TapeTo avoid surface damage
Adhesive tapeTo avoid surface damage
Double±stick tape
Adhesive
Cleaner
Shop rag
Knife
Sealer gun
Brush
Putty spatula
Glass plate or similar object
Wooden block or similar object
Heat light
Piano wire
Rope (no projections, difficult to break)Seat belt pretensioner
Tire with disk wheel Width: 185 mm (7.28 in.)
Inner diam: 360 mm (14.17 in.)Seat belt pretensioner
Vinyl bagSeat belt pretensioner

± SERVICE SPECIFICATIONSENGINE MECHANICAL
SS±7
129 Author: Date:
2001 PRIUS (RM778U) Cylinder head
Warpage
Cylinder brock side Maximum
Intake manifold sideMaximum
Exhaust manifold side Maximum
Valve seat
Refacing angle
Contacting angle
Contacting width
Valve guide bushing bore diameter STD
O/S 0.05
0.05 mm (0.0020 in.)
0.01 mm (0.0394 in.)
0.01 mm (0.0394 in.)
20°, 45°, 75°
45°
1.0 ± 1.4 mm (0.039 ± 0.055 in.)
9.685 ± 9.706 mm (0.38130 ± 0.38213 in.)
9.735 ± 9.756 mm (0.38327 ± 0.38493 in.)
Valve guide
bushingInside diameter
Protrusion height5.010 ± 5.030 mm (0.19724 ± 0.19803 in.)
9.0 ± 9.4 mm (0.354 ± 0.370 in.)
Valve
Valve overall length STD Intake
Exhaust
Minimum Intake
Exhaust
Valve face angle
Stem diameterIntake
Exhaust
Stem oil clearance STD Intake
Exhaust
Maximum Intake
Exhaust
Margin thickness STD
Minimum89.25 mm (3.5138 in.)
87.90 mm (3.4606 in.)
88.95 mm (3.5020 in.)
87.60 mm (3.4488 in.)
44.5°
4.970 ± 4.985 mm (0.19567 ± 0.19626 in.)
4.965 ± 4.980 mm (0.19547 ± 0.19606 in.)
0.025 ± 0.060 mm (0.00098 ± 0.00236 in.)
0.030 ± 0.065 mm (0.00118 ± 0.00256 in.)
0.08 mm (0.0031 in.)
0.10 mm (0.0039 in.)
1.00 ± 1.15 mm (0.039 ± 0.045 in.)
0.7 mm (0.028 in.)
Valve spring
Deviation Maximum
Angle (Reference) Maximum
Free length
Installed tension at 32.5 mm (1.280 in.)
Maximum working tension at 23.9 mm (0.941 in.)1.6 mm (0.063 in.)
2°
59.77 mm (2.353 in.)
140 ± 154 N (14.3 ± 15.7 kgf, 31.5 ± 34.6 lbf)
180 ± 198 N (18.4 ± 20.2 kgf, 40.4 ± 44.8 lbf)
Valve lifter
Lifter diameter
Lifter bore diameter
Oil clearance STD
Maximum30.966 ± 30.976 mm (1.21913 ± 1.21952 in.)
31.009 ± 31.025 mm (1.22082 ± 1.22145 in.)
0.031 ± 0.059 mm(0.00122 ± 0.00232 in.)
0.1 mm (0.004 in.)
Camshaft
Thrust clearance STD
Maximum
Journal oil clearance STD
Maximum
Journal diameter No. 1
Others
Circle run out Maximum
Cam lobe height
STD Intake
Exhaust
Minimum Intake
Exhaust0.040 ± 0.095 mm (0.0016 ± 0.0037 in.)
0.11 mm (0.0043 in.)
0.040 ± 0.095 mm (0.00157 ± 0.00374 in.)
0.115 mm (0.00453 in.)
34.449 ± 34.465 (1.35626 ± 1.35689 in.)
22.949 ± 22.965 (0.90350 ± 0.90413 in.)
0.03 mm (0.0012 in.)
42.310 ± 42.410 mm (1.62637 ± 1.66968 in.)
44.046 ± 44.146 mm (1.73409 ± 1.73803 in.)
42.16 mm (1.6598 in.)
43.90 mm (1.7283 in.)
Intake
manifoldWarpage Maximum0.10 mm (0.0039 in.)
Exhaust
manifoldWarpage Maximum0.70 mm (0.0276 in.)

A11260
Seal Width:
4 ± 5 mmFIPG
FIPG
A11261
Seal
Packing
Seal
Packing
Seal Width
4 ± 5 mm EM±22
± ENGINE MECHANICALTIMING CHAIN
2001 PRIUS (RM778U)
3. INSTALL TIMING CHAIN COVER AND WATER PUMP
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the timing
chain cover, cylinder head and cylinder block.

Using a razor blade and a gasket scraper, remove
all the old packing (FIPG) material from the gasket
surfaces and sealing grooves.

Thoroughly clean all components to remove all the
loose material.

Using a non±residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the timing chain cover as shown in
the illustration.
Seal packing:
Part No. 08826 ± 00100 or equivalent

Install a nozzle that has been cut to a 4 ± 5 mm (0.16
± 0.20 in.) opening.

FIPG shall be accumulated in the groove for FIPG
to a depth of 2.5 mm (0.10 in.) or more.
HINT:
Avoid applying an excessive amount to the surface.

Parts must be assembled within 3 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(c) Apply seal packing to 4 locations as shown in the illustra-
tion.
Seal packing:
Part No. 08826 ± 00080 or equivalent

Install a nozzle that has been cut to a 4 ± 5 mm (0.16
± 0.20 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.

Parts must be assembled within 3 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(d) Install 2 new O±rings to the cylinder block and oil pan No.
1.

EM2534
Overall Length
A01073
45° Carbide
CutterResiduary
Width
Resurface
A01074
Width
EM0185
45°20°
1.0 ± 1.4 mm
EM0186
75°
1.0 ± 1.4 mm45°
EM±36
± ENGINE MECHANICALCYLINDER HEAD
2001 PRIUS (RM778U)
(d) Check the valve overall length.
Standard overall length:
Intake 89.25 mm (3.5138 in.)
Exhaust 87.90 mm (3.4606 in.)
Minimum overall length:
Intake 88.95 mm (3.5020 in.)
Exhaust 87.60 mm (3.4488 in.)
If the overall length is less than minimum, replace the valve.
(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
11. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45° carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
(b) Check the valve seating position.
Apply a light coat of prussian blue (or white lead) to the
valve face. Lightly press the valve against the seat. Do not
rotate valve.
(c) Check the valve face and seat for the following:

If blue appears 360° around the face, the valve is
concentric. If not, replace the valve.

If blue appears 360° around the valve seat, the
guide and face are concentric. If not, resurface the
seat.

Check that the seat contact is in the middle of the
valve face with the following width:
1.0 ± 1.4 mm (0.039 ± 0.055 in.)
If not, correct the valve seats as follows:
(1) If the seating is too high on the valve face, use 20°
and 45° cutters to correct the seat.
(2) If the seating is too low on the valve face, use 75°
and 45° cutters to correct the seat.

A10464
Seal Width 2 ± 3 mm
A11271
1
25
6
34
78910
11
12151314
BCAB
± ENGINE MECHANICALCYLINDER BLOCK
EM±81
2001 PRIUS (RM778U)
12. INSTALL OIL PAN NO. 1
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surface of the oil pan No.
1 and cylinder block.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing grooves.

Thoroughly clean all components to remove all the
loose material.

Using a non±residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the oil pan No. 1 as shown in the
illustration.
Seal packing:
Part No. 08826±00080 or equivalent

Install a nozzle that has been cut to a 2 ± 3 mm (0.08
± 0.12 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.

Parts must be assembled within 3 minutes of ap-
plication. Otherwise the material must be remove d
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install new O±rings to the cylinder block.
(d) Using a plastic±faced hammer, lightly tap the oil pan No.
1 to ensure a proper fit.
(e) Install and uniformly tighten the 13 bolts, in several
passes, in the sequence shown.
Torque: 24 N´m (245 kgf´cm, 18 ft´lbf)
HINT:
Each bolt length in indicated in the illustration.
A: 49 mm (1.929 in.)
B: 88 mm (3.465 in.)
C: 144 mm (5.669 in.)
13. INSTALL REAR CRANKSHAFT OIL SEAL
(See page EM±77)
HINT:
Wipe seal packing away from the contact surface of the cylinder
block assembly and oil seal.