TOYOTA PRIUS 2001 Service Repair Manual

A01234
New lifter thickness mm (in.)
Lifter
No.
ThicknessLifter
No.ThicknessLifter
No.Thickness
5.540 (0.2181)
5.560 (0.2189)
5.580 (0.2197)
5.600 (0.2205)
5.620 (0.2213)
5.640 (0.2220)
5.660 (0.2228)
5.680 (0.2236)
5.700 (0.2244)
5.720 (0.2252)
5.740 (0.2260) 06
08
10
12
14
16
18
20
22
24
26
2830
32
34
36
38
40
42
44
46
48
50
5254
56
58
60
62
64
66
68
70
72
74 5.300 (0.2087)
5.320 (0.2094)
5.340 (0.2102)
5.360 (0.2110)
5.380 (0.2118)
5.400 (0.2126)
5.420 (0.2134)
5.440 (0.2142)
5.460 (0.2150)
5.480 (0.2157)
5.500 (0.2165)
5.520 (0.2173) 5.060 (0.1992)
5.080 (0.2000)
5.100 (0.2008)
5.120 (0.2016)
5.140 (0.2024)
5.160 (0.2031)
5.180 (0.2039)
5.200 (0.2047)
5.220 (0.2055)
5.240 (0.2063)
5.260 (0.2071)
5.280 (0.2079)
Valve Lifter Selection Chart (Intake)
Intake valve clearance (Cold):
0.15 ± 0.25 mm (0.006 ± 0.010 in.)
EXAMPLE: The 5.250 mm (0.2067 in.) lifter is installed, and
the measured clearance is 0.400 mm (0.0157 in.).
Replace the 5.250 mm (0.2067 in.) lifter with a new No. 46 lifter.
EM±8
± ENGINE MECHANICALVALVE CLEARANCE
1124 Author: Date:
2001 PRIUS (RM778U)

A01235
New lifter thickness mm (in.)
Lifter
No.
ThicknessLifter
No.ThicknessLifter
No.Thickness
5.540 (0.2181)
5.560 (0.2189)
5.580 (0.2197)
5.600 (0.2205)
5.620 (0.2213)
5.640 (0.2220)
5.660 (0.2228)
5.680 (0.2236)
5.700 (0.2244)
5.720 (0.2252)
5.740 (0.2260) 06
08
10
12
14
16
18
20
22
24
26
2830
32
34
36
38
40
42
44
46
48
50
5254
56
58
60
62
64
66
68
70
72
74 5.300 (0.2087)
5.320 (0.2094)
5.340 (0.2102)
5.360 (0.2110)
5.380 (0.2118)
5.400 (0.2126)
5.420 (0.2134)
5.440 (0.2142)
5.460 (0.2150)
5.480 (0.2157)
5.500 (0.2165)
5.520 (0.2173) 5.060 (0.1992)
5.080 (0.2000)
5.100 (0.2008)
5.120 (0.2016)
5.140 (0.2024)
5.160 (0.2031)
5.180 (0.2039)
5.200 (0.2047)
5.220 (0.2055)
5.240 (0.2063)
5.260 (0.2071)
5.280 (0.2079)
Valve Lifter Selection Chart (Exhaust)
Exhaust valve clearance (Cold):
0.25 ± 0.35 mm (0.010 ± 0.014 in.)
EXAMPLE: The 5.340 mm (0.2102 in.) lifter is installed, and
the measured clearance is 0.440 mm (0.0173 in.).
Replace the 5.340 mm (0.2102 in.) lifter with a new No. 48 lifter.
± ENGINE MECHANICALVALVE CLEARANCE
EM±9
1125 Author: Date:
2001 PRIUS (RM778U)

A11246
A11245
Timing Marks
A11252
Matchmarks
EM±10
± ENGINE MECHANICALVALVE CLEARANCE
1126 Author: Date:
2001 PRIUS (RM778U)
(l) Reinstall the valve lifters (See page EM±43).
(m) Align the crankshaft pulley groove with the timing mark º0º
of the timing chain cover.
(n) Hold the timing chain, and place the exhaust camshaft
and timing sprocket assembly.
(o) Align the matchmarks on the timing chain and camshaft
timing sprocket.
(p) Reinstall the intake camshaft, valve timing controller as-
sembly and camshaft bearing caps (See page EM±45).
(q) Remove the bar from the timing chain tensioner.
(r) Check that both timing marks on the camshaft timing
sprocket and valve timing controller assembly are facing
right upas shown in the illustration.
(s) Check that the matchmarks on the timing chain and cam-
shaft timing sprockets.
(t) Install a new plug to the timing chain cover.
Torque: 15 N´m (150 kgf´cm, 11 ft´lbf)
(u) Recheck the valve clearance (See procedure in step 3).
(v) Check the valve timing (See page EM±19).
5. REINSTALL CYLINDER HEAD COVER
(See page EM±21)

EM173±04
A13942
Hood to Cowl Top
seal
VSV for EVAPR/B (ABS) Air Cleaner
Assembly
RH Engine Mounting
Insulator Engine Coolant
Reservoir Tank
Engine Under
Cover RH
N´m (kgf´cm, ft´lbf) : Specified torqueOuter Front Cowl
Top Panel Air Inlet
60 (612, 44)
52 (530, 38)
52 (530, 38)
26 (265, 19)Brake Reservoir
Tank
Wiper Motor and
Wiper Link
Assembly
Cowl Top Ventilator
Lower LH
Cowl Top Ventilator
Lower RH
Wiper Arm
7 (71, 62 in. lbf)
26 (265, 19)
± ENGINE MECHANICALTIMING CHAIN
EM±13
1129 Author: Date:
2001 PRIUS (RM778U)
TIMING CHAIN
COMPONENTS

A13926
N´m (kgf´cm, ft´lbf)

Non±reusable part: Specified torque RH Engine Mounting Bracket
Timing Chain Cover
Cylinder Head CoverIgnition Ciol
(w/ Igniter)
PCV Hose
Front Crankshaft
Oil Seal Crankshaft Pulley
Gasket
Water Pump Pulley
Water Pump
GasketChain Tensioner
Slipper
Chain Vibration Damper Tinming Chain
Timing Chain
TensionerPin




O±Ring


O±Ring

11 (110, 8)
15 (150, 11)
128 (1,300, 94)
55 (561, 41)
10 (100, 7)
EM±14
± ENGINE MECHANICALTIMING CHAIN
1130 Author: Date:
2001 PRIUS (RM778U)

EM1IU±03
A13907
A13908
A13934
A13943
± ENGINE MECHANICALTIMING CHAIN
EM±15
2001 PRIUS (RM778U)
REMOVAL
1. DISCONNECT BATTERY NEGATIVE (±) TERMINAL
AND HV BATTERY SERVICE PLUG
(See page HV±1)
2. REMOVE OUTER FR COWL TOP PANEL ASSEMBLY
(See page BO±32)
3. REMOVE RH ENGINE UNDER COVER
4. DRAIN ENGINE COOLANT
5. REMOVE AIR CLEANER ASSEMBLY
(a) Disconnect the MAF meter connector.
(b) Disconnect the EVAP hose from the air cleaner case.
(c) Loosen the 2 hose clamps.
(d) Remove the 3 bolts and air cleaner assembly.
6. 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.
(c) Remove the 3 bolts and reservoir tank bracket.
7. DISCONNECT CONNECTORS
(a) Disconnect the 4 ignition connectors.
(b) Disconnect the 4 injector connectors.
(c) Disconnect the 2 VSV connectors.
(d) Disconnect the camshaft position sensor connector.
(e) Disconnect the water temperature connector.
(f) Disconnect the Camshaft timing oil control valve connec-
tor.
8. REMOVE AIR INLET
9. REMOVE ENGINE COOLANT RESERVOIR TANK
10. REMOVE VSV FROM ENGINE MOUNTING INSULA-
TOR
11. REMOVE DRIVE BELT

A13927
A13928
B11761
A11222
A11244
EM±16
± ENGINE MECHANICALTIMING CHAIN
2001 PRIUS (RM778U)
12. REMOVE RH ENGINE MOUNTING INSULATOR
(a) Set the jack to the engine.
HINT:
Place the wooden block between the jack and engine.
(b) Remove the 5 bolts, 2 nuts and RH engine mounting insu-
lator.
13. DISCONNECT ENGINE WIRE FROM CYLINDER HEAD
COVER
Remove the 3 bolts and disconnect the engine wire from the cyl-
inder head.
14. REMOVE CYLINDER HEAD COVER
(a) Remove the ignition coils (See page IG±6)
(b) Remove the 2 PCV hoses from the cylinder head cover.
(c) Remove the 7 bolts, 2 seal washers, 2 nuts, cylinder head
cover and gasket.
15. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with timing
mark º0º of the timing chain cover.

A11245
Timing Marks
A11253
SST
SST
A11254
SST
A11258
A11255
± ENGINE MECHANICALTIMING CHAIN
EM±17
2001 PRIUS (RM778U)
(b) Check that both timing marks on the camshaft timing
sprocket and valve timing controller assembly are facing
right up as shown in the illustration.
If not, turn the crankshaft 1 revolution (360°) and align the
marks as above.
16. REMOVE CRANKSHAFT PULLEY
(a) Using SST, remove the pulley bolt.
SST 09213±70010, 09330±00021
(b) Remove the crankshaft pulley and pin.
HINT:
If necessary, remove the pulley with SST.
SST 09950±50012 (09951±05010, 09952±05010,
09953±05020, 09954±05020)
17. REMOVE CRANKSHAFT POSITION SENSOR
(See page IG±12)
18. REMOVE RH ENGINE MOUNTING BRACKET
Remove the 4 bolts and mounting bracket.
19. REMOVE WATER PUMP (See page CO±6)
20. REMOVE OIL CONTROL VALVE (See page EM±29)
21. REMOVE TIMING CHAIN COVER
(a) Remove the 13 bolts and nut.
(b) Using a torx wrench socket (E8), remove the stud bolt.
(c) Remove the timing chain cover by prying the portions be-
tween the cylinder head and cylinder block with a screw-
driver.
NOTICE:
Be careful not to damage the contact surfaces of the timing
chain cover, cylinder head and cylinder block.

EM±18
± ENGINE MECHANICALTIMING CHAIN
2001 PRIUS (RM778U)
(d) Remove the 2 O±rings from the cylinder block and oil pan
No.1.
22. REMOVE CHAIN TENSIONER
Remove the 2 bolts and chain tensioner.
23. REMOVE CHAIN TENSIONER SLIPPER
24. REMOVE CHAIN VIBRATION DAMPER
Remove the 2 bolts and damper.
25. REMOVE TIMING CHAIN

EM1IV±02
A11224
ATDC20°Mark Link
Timing Mark
30°
Timing Mark
Mark Link
A11225
± ENGINE MECHANICALTIMING CHAIN
EM±21
2001 PRIUS (RM778U)
INSTALLATION
1. INSTALL TIMING CHAIN
(a) After setting the crankshaft at ATDC40±140 °, set cams
of intake and exhaust timing sprockets at ATDC 20 ° and
then the reset the crankshaft at ATDC 20 °.
(b) Install the chain vibration damper with the 2 bolts.
Torque: 9.0 N´m (92 kgf´cm, 80 in.´lbf)
(c) Align the match marks of timing chain mark plate (Yellow),
camshaft timing sprocket, camshaft timing gear and
crankshaft timing sprocket to install the timing chain as
shown in the illustration.
HINT:
To prevent the exhaust camshaft from spring back turn it using
a wrench and set it at the mark on a chain.
(d) Install the chain tensioner slipper.
2. INSTALL CHAIN TENSIONER
(a) While rotating the lock plate of the tensioner up±ward,
push in the plunger of the tensioner as shown in the il-
lustration.
(b) While rotating the lock plate of the tensioner down±ward,
insert a bar of 2.5 mm (0.098 in.) into the holes in the lock
plate.
(c) Install the chain tensioner with the 2 bolts.
Torque: 9.0 N´m (92 kgf´cm, 80 in.´lbf)
(d) Remove the bar from the chain tensioner.
(e) Check that the tension between the intake and exhaust
camshaft timing sprocket.