TOYOTA PRIUS 2001 Service Repair Manual

EM16M±02
A11230
For Radiator Hose
For Water Bypass Hose 15 mm18 mm
A11231
Adhesive
A11232
AB
A01063
SST
± ENGINE MECHANICALCYLINDER HEAD
EM±43
2001 PRIUS (RM778U)
REASSEMBLY
HINT:

Thoroughly clean all parts to be assembled.

Before installing the parts, apply fresh engine oil to all slid-
ing and rotating surfaces.

Replace oil seals with new ones.
1. INSTALL WATER HOSE UNIONS
HINT:
When using a new cylinder head, water hose unions must be
installed.
(a) Mark the standard position away from the edge, onto the
water hose union.
(b) Apply adhesive to the water hose union hole of the cylin-
der head.
Adhesive:
Part No.08833±00070, THREE BOND 1324 or
equivalent
(c) Using a press, press in a new water hose union until there
is protruding from the cylinder head.
Standard protrusion:
A 29 mm (1.14 in.)
B 44 mm (1.73 in.)
NOTICE:
Avoid pressing a new water hose union in too far by mea-
suring the amount of protrusion while pressing.
2. INSTALL VALVES
(a) Using SST, push in a new oil seal.
SST 09201±41020

S05923
Intake Exhaust
Mark
ºNOKº
Gray Surface
Light Brown Surface
A01065
(1)
(2)(3)
(4)
A01061
SST
A07307
EM±44
± ENGINE MECHANICALCYLINDER HEAD
2001 PRIUS (RM778U)
HINT:
The intake valve oil seal is light brown and the exhaust valve oil
seal is gray.
NOTICE:
Pay much attention assembling the oil seal for intake and
exhaust. Assembling the wrong one may cause a failure.
(b) Install the valve (1), spring (2), valve spring (3), and spring
retainer (4).
(c) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202±70020 (09202±00010)
(d) Using a plastic±faced hammer and the valve stem (not in
use) tip wound with vinyl tape, lightly tap the valve stem
tip to ensure a proper fit.
NOTICE:
Be careful not to damage the valve stem tip.
3. INSTALL VALVE LIFTERS
(a) Install the valve lifter.
(b) Check that the valve lifter rotates smoothly by hand.

EM1IY±02
A11249
Lod No.
A11228
84259
106137
A12126
Front90°90°
± ENGINE MECHANICALCYLINDER HEAD
EM±45
2001 PRIUS (RM778U)
INSTALLATION
HINT:

Thoroughly clean all parts to be assembled.

Before installing the parts, apply fresh engine oil to all slid-
ing and rotating surfaces.

Replace all gaskets and oil seals with new ones.
1. PLACE CYLINDER HEAD ON CYLINDER BLOCK
(a) Place a new cylinder head gasket on the cylinder block
surface with the Lod No. stamp upward.
NOTICE:
Be careful of the installation direction.
(b) Place the cylinder head quietly in order not to damage the
gasket with the bottom part of the head.
2. INSTALL CYLINDER HEAD BOLTS
HINT:

The cylinder head bolts are tightened in 2 progressive
steps (steps (b) and (d)).

If any cylinder head bolt is broken or deformed, replace
it.
(a) Apply a light coat if engine oil on the threads and under
the heads of the cylinder head bolts.
(b) Using a 10 mm bi±hexagon wrench, install and uniformly
tighten the 10 cylinder head bolts and plate washers, in
several passes, in the sequence shown.
Torque: 29.4 N´m (300 kgf´cm, 22 ft´lbf)
If any one of the cylinder head bolts does not meet the torque
specification, replace the cylinder head bolt.
(c) Mark the front of the cylinder head bolt with paint.
(d) Retighten the cylinder head bolts by 90° and 90° in the
numerical order shown.
(e) Check that the paint mark is now at a 180° angle to the
front.
(f) Install the bolt holding the water bypass pipe to the cylin-
der head.
Torque: 9.0 N´m (92 kgf´cm, 80 in.´lbf)

A12945
No.1 Cam Lobe
A12946
A12943
9
9
96
5
2
1
4
3
8
7 EM±46
± ENGINE MECHANICALCYLINDER HEAD
2001 PRIUS (RM778U)
(g) Connect the upper radiator hose to the water hose
unions.
(h) Connect the heater hose to the water hose unions.
3. INSTALL CAMSHAFTS
(a) Place the 2 camshafts on the cylinder head with the No.1
cam lobes facing as shown the illustration.
(b) Install the bearing caps in their proper locations.
HINT:
No. 2 camshaft bearing cap has a number and front mark.
(c) Apply a light coat of engine oil on the threads and under
the heads of the bearing cap bolts.
(d) Install and uniformly tighten the 19 bearing cap bolts.
After tightening the No.1 camshaft bearing cap, tighten
then in several passes, in the sequence shown.
Torque:
No. 1 23 N´m (235 kgf´cm, 17 ft´lbf)
No. 2 12.7 N´m (130 kgf´cm, 10 ft´lbf)
4. INSTALL VALVE TIMING CONTROLLER ASSEMBLY
AND CAMSHAFT TIMING SPROCKET
(a) Apply engine oil in the rage from the tip of the intake cam-
shaft to 16 mm from that tip.
(b) Except leaded gasoline spec:
Align the timing mark on the valve timing controller as-
sembly with the knock pin, and install the value timing
controller assembly to the camshaft.
NOTICE:
Do not push valve timing controller assembly to the cam-
shaft forcibly when installing it.
(c) Align the knock pin hole in the camshaft timing sprocket
with the knock pin of the camshaft, and install the sprock-
et to the camshaft.

A13933
A11226
A13932
± ENGINE MECHANICALCYLINDER HEAD
EM±47
2001 PRIUS (RM778U)
(d) Temporarily install the timing sprocket bolt.
(e) Hold the hexagon head portion of the camshaft with a
wrench, and install the bolt.
Torque: 64 N´m (650 kgf´cm, 47 ft´lbf)
5. CHECK AND ADJUST VALVE CLEARANCE
(See page EM±5)
6. INSTALL CYLINDER HEAD COVER
(See page EM±21)
7. INSTALL OIL CONTROL VALVE
8. INSTALL OIL FILTER CAP
9. INSTALL PCV VALVE
10. INSTALL ECT SENSOR
(See page SF±49)
11. INSTALL CAMSHAFT POSITION SENSOR
(See page IG±10)
12. INSTALL TIMING CHAIN COVER
(See page EM±21)
13. INSTALL EXHAUST MANIFOLD
(a) Install a new gasket and the exhaust manifold with the 3
bolts 2 nuts. Uniformly tighten the bolts and nuts in sever-
al passes.
Torque: 27 N´m (275 kgf´cm, 20 ft´lbf)
(b) Install the upper heat insulator with the 4 bolts.
Torque: 8.0 N´m (82 kgf´cm, 71 in.´lbf)
14. INSTALL EXHAUST MANIFOLD STAY
Install the manifold stay with the 3 bolts. Alternately tighten the
bolts.
Torque: 37 N´m (377 kgf´cm, 27 ft´lbf)
15. CONNECT FRONT EXHAUST PIPE TO EXHAUST
MANIFOLD
(a) Place a new gasket to the exhaust manifold.
(b) Install the 2 bolts and 2 springs holding the front exhaust
pipe to the exhaust manifold.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)

A13935
A13934
A13907
EM±48
± ENGINE MECHANICALCYLINDER HEAD
2001 PRIUS (RM778U)
16. INSTALL INTAKE MANIFOLD
Install a new gasket, the intake manifold and 2 brackets with the
2 bolts and 2 nuts. Uniformly tighten the bolts and nuts in sever-
al passes.
Torque: 20 N´m (204 kgf´cm, 15 ft´lbf)
17. CONNECT ENGINE WIRE TO CYLINDER HEAD
(a) Install the engine wire protector to the cylinder head cover
with the 2 bolts.
(b) Connect the water ECT sensor connector.
(c) Connect the camshaft position sensor connector.
(d) Connect the oil control valve connector.
(e) Connect the 4 injector connectors.
18. INSTALL THROTTLE BODY
(See page SF±31)
19. INSTALL PCV HOSES
20. INSTALL SPARK PLUGS
(See page IG±1)
21. INSTALL IGNITION COILS (See page IG±7)
22. 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.
23. INSTALL CONVERTER AND INVERTER ASSEMBLY
(See page HV±18)
24. INSTALL OUTER FR COWL TOP PANEL ASSEMBLY
(See page BO±32)
25. FILL WITH ENGINE COOLANT
26. FILL WITH HV COOLANT
27. INSTALL ENGINE UNDER COVERS
28. CONNECT BATTERY NEGATIVE (±) TERMINAL AND
HV BATTERY SERVICE PLUG (See page HV±1)

± ENGINE MECHANICALCYLINDER HEAD
EM±49
2001 PRIUS (RM778U)
29. ROAD TEST VEHICLE
Check for abnormal noises, shock slippage, correct shift points
and smooth operation.
30. RECHECK ENGINE COOLANT AND HV COOLANT

EM1IZ±02
A13904
Front BumperR/B (ABS)
Air Cleaner
Assembly Engine Coolant
Reservoir Tank
Engine Under
CoverOuter Front Cowl
Top Panel Air Inlet
Brake Reservoir
Tank
Wiper Motor and
Wiper Link
Assembly
Cowl Top Ventilator
Lower LH
Cowl Top Ventilator
Lower RH
Wiper Arm
Hood to Cowl Top
Seal
N´m (kgf´cm, ft´lbf) : Specified torque
26 (265, 19)
7 (71, 62 in. lbf)
26 (265, 19)
11.5 (117, 8)
Head Light RH
EM±50
± ENGINE MECHANICALENGINE UNIT
1166 Author: Date:
2001 PRIUS (RM778U)
ENGINE UNIT
COMPONENTS

A13905
RH Drive ShaftA/C Compressor
Gasket Engine Mounting
Insulator RH
Torque Rod
N´m (kgf´cm, ft´lbf) : Specified torqueEngine Mounting
Insulator LH Drive Belt
25 (255, 18)
62 (630, 46)
216 (2,203, 159)
43 (440, 32)
Converter and Inverter
Assembly
Front Exhaust Pipe Vacuum Hose for HCAC
Intermediate Extension
Fuel Tube
80 (816, 59)
52 (530, 38)
LH Drive Shaft








100 (1,020, 74)
60 (612, 74)
142 (1,448, 105)113 (1,152, 83)
Gasket


Shift Lever
Cable
Non±reusable part


62 (630, 46)
157 (1,601, 116)
± ENGINE MECHANICALENGINE UNIT
EM±51
1167 Author: Date:
2001 PRIUS (RM778U)

A13906
N´m (kgf´cm, ft´lbf) : Specified torque
16 (163, 12)
Engine Unit
Fly Wheel
x6Damper Disc
x6 Damper Disc Spring
Transaxle
Non±reusable part



49 (500, 36)
See page EM±58 1st:
2nd: 90°
33 (337, 24)
EM±52
± ENGINE MECHANICALENGINE UNIT
1168 Author: Date:
2001 PRIUS (RM778U)