TOYOTA PRIUS 2001 Service Repair Manual

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.

A11271
A11272
A10452
A10453
A10454
± ENGINE MECHANICALCYLINDER BLOCK
EM±65
2001 PRIUS (RM778U)
14. REMOVE OIL PAN NO. 1
(a) Uniformly loosen and remove the 13 bolts, in several
passes, in the sequence shown.
(b) Using screwdriver remove the oil pan No. 1 by prying the
portions between the cylinder block and oil pan No. 1.
(c) Remove the 2 O±rings from the cylinder block.
15. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while mov-
ing the connecting rod back and forth.
Standard thrust clearance:
0.16 ± 0.36 mm (0.0063 ± 0.0142 in.)
Maximum thrust clearance:
0.36 mm (0.0142 in.)
If the thrust clearance is greater than maximum, replace the
connecting rod assembly(s). If necessary, replace the crank-
shaft.
16. REMOVE CONNECTING ROD CAPS AND CHECK OIL
CLEARANCE
(a) Check the matchmarks on the connecting rod and cap are
aligned to ensure correct reassembly.
(b) Remove the 2 connecting rod cap bolts.
(c) Using the 2 removed connecting rod cap bolts, remove
the connecting rod cap and lower bearing by wiggling the
connecting rod cap right and left.
HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d) Clean the crank pin and bearing.
(e) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings.
If necessary, replace the crankshaft.

A10455
Plastigage
A10456
A10457
A01198
Mark
1, 2 or 3
Mark
1, 2 or 3
EM±66
± ENGINE MECHANICALCYLINDER BLOCK
2001 PRIUS (RM778U)
(f) Lay a strip of Plastigage the crank pin.
(g) Install the connecting rod cap with the 2 bolts.
(See page EM±78)
Torque:
1ST 15 N´m (150 kgf´cm, 11 ft´lbf)
2ND Turn 90 °
NOTICE:
Do not turn the crankshaft.
(h) Remove the 2 bolts, connecting rod cap and lower bear-
ing. (See procedure (b) and (c) above)
(i) Measure the Plastigage at its widest point.
Standard oil clearance:
0.016 ± 0.040 mm (0.0006 ± 0.0016 in.)
Maximum oil clearance:
0.06 mm (0.0024 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, grind or replace the crankshaft.
HINT:
If replacing a bearing, replace it with one having the same num-
ber as marked on the connecting rod. There are 3 sizes of stan-
dard bearings, marked º1º, º2º and º3º accordingly.
Reference
Standard bearing center wall thickness
Markmm (in.)
º1º1.488 ± 1.492 (0.0586 ± 0.0587)
º2º1.492 ± 1.496 (0.0587 ± 0.0589)
º3º1.496 ± 1.500 (0.0589 ± 0.0591)
(j) Completely remove the plastigage.

A01166
A10458
A10459
A10460
± ENGINE MECHANICALCYLINDER BLOCK
EM±67
2001 PRIUS (RM778U)
17. REMOVE PISTON AND CONNECTING ROD
ASSEMBLIES
(a) Using a ridge reamer, remove all the carbon from the top
of the cylinder.
(b) Push the piston, connecting rod assembly and upper
bearing through the top of the cylinder block.
HINT:

Keep the bearings, connecting rod and cap together.

Arrange the piston and connecting rod assemblies in the
correct order.
18. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while mov-
ing the crankshaft back and forth.
Standard thrust clearance:
0.09 ± 0.19 mm (0.0035 ± 0.0075 in.)
Maximum thrust clearance:
0.3 mm (0.012 in.)
If the thrust clearance is greater than maximum, replace the
thrust washer as a set.
Thrust washer thickness:
2.430 ± 2.480 mm (0.09567 ± 0.09764 in.)
19. REMOVE BEARING CAPS AND CHECK OIL CLEAR-
ANCE
(a) Uniformly loosen and remove the 10 bearing cap bolts in
several passes in the sequence shown.
(b) Using the 2 removed bearing cap bolts, remove the bear-
ing cap and lower bearing by wiggling the bearing cap
right and left.
HINT:
Keep the lower bearing inserted with the bearing cap.
(c) Lift out the crankshaft.
HINT:
Keep the upper bearings and thrust washers together with the
cylinder block.
(d) Clean each main journal and bearing.

A10461
A10462
A10463
No. 1No. 2
No. 3
No. 4No. 5
No. 5
No. 4
No. 3
No. 2
No. 1
Number
Mark
Total number º º: Number mark
Cylinder block (A)
+
Crankshaft (B)
Use bearing0 ± 2 3 ± 5 6 ± 8 9 ±11
º1º
EXAMPLE: Cylinder block º4º (A)
+ Crankshaft º3º (B)
= Total number 7 (Use bearing º3º)º2º º3º º4º EM±68
± ENGINE MECHANICALCYLINDER BLOCK
2001 PRIUS (RM778U)
(e) Check each main journal and bearing for pitting and
scratches.
If the journal or bearing is damaged, replace the bearing.
If necessary, grind or replace the crankshaft.
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of plastigage acrose each journal.
(h) Install the bearing caps (See page EM±45).
Torque:
1ST 22 N´m (220 kgf´cm, 16 ft´lbf)
2ND Turn 90 °
NOTICE:
Do not turn the crankshaft.
(i) Remove the bearing caps (See procedure (a) and (b)
above).
(j) Measure the plastigage at its widest point.
Standard oil clearance:
0.010 ± 0.023 mm (0.0004 ± 0.0009 in.)
Maximum oil clearance:
0.07 mm (0.0028 in.)
If the oil clearance is greater then maximum, replace the bear-
ings. If necessary, replace the crankshaft.
HINT:
If using a standard bearing, replace it with one having the same
number. If the number of the bearing cannot be determined, se-
lect the correct bearing by adding together the numbers im-
printed on the cylinder block and crankshaft, then selecting the
bearing with the same number as the total. There are 4 sizes
of standard bearings, marked º1º, º2º, º3º and º4º accordingly.

A12947
A12948
± ENGINE MECHANICALCYLINDER BLOCK
EM±69
2001 PRIUS (RM778U)
Reference
ItemMarkmm (in.)
Cylinder block main journal bore diameter (A)º0º
º1º
º2º
º3º
º4º
º5º
º6º50.000 ± 50.003 (1.96850 ± 1.96862)
50.003 ± 50.005 (1.96862 ± 1.96870)
50.005 ± 50.007 (1.96870 ± 1.96878)
50.007 ± 50.010 (1.96878 ± 1.96889)
50.010 ± 50.012 (1.96889 ± 1.96897)
50.012 ± 50.014 (1.96897 ± 1.96905)
50.014 ± 50.016 (1.96905 ± 1.96913)
Crankshaft main journal diameter (B)º0º
º1º
º2º
º3º
º4º
º5º46.000 ± 46.002 (1.81102 ± 1.81110)
46.002 ± 46.004 (1.81110 ± 1.81118)
46.004 ± 46.006 (1.81118 ± 1.81126)
46.006 ± 46.008 (1.81126 ± 1.81133)
46.008 ± 46.010 (1.81133 ± 1.81141)
46.010 ± 46.012 (1.81141 ± 1.81149)
Standard bearing center wall thicknessº1º
º2º
º3º
º4º1.992 ± 1.995 (0.07843 ± 0.07854)
1.995 ± 1.998 (0.07854 ± 0.07866)
1.998 ± 2.001 (0.07866 ± 0.07878)
2.001 ± 2.004 (0.07878 ± 0.07890)
(k) Completely remove the Plastigage.
20. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the 5 upper main bearings and 2 thrust washers
from the cylinder block.
HINT:
Arrange the main bearings and thrust washers in the correct or-
der.
21. CHECK FIT BETWEEN PISTON AND PISTON PIN
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
22. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the oil ring by hand.
HINT:
Arrange the piston rings in the correct order only.

A12963
SSTSST
SST
EM±70
± ENGINE MECHANICALCYLINDER BLOCK
2001 PRIUS (RM778U)
23. DISCONNECT CONNECTING ROD FROM PISTON
Using SST, press out the piston pin from the piston. Remove the
piston.
SST 09221±25026 (09221±00021, 09221±00030,
09221±00190, 09221±00141, 09221±00150)
HINT:

The piston and pin are a matched set.

Arrange the pistons, pins, rings, connecting rods and
bearings in correct order.

EM17D±03
A01165
A01169
A01167
± ENGINE MECHANICALCYLINDER BLOCK
EM±71
2001 PRIUS (RM778U)
INSPECTION
1. REMOVE GASKET MATERIAL
Using a gasket scraper, remove all the gasket material from the
top surface of the cylinder block.
2. CLEAN CYLINDER BLOCK
Using a soft brush and solvent, thoroughly clean the cylinder
block.
NOTICE:
If the cylinder is washed at high temperatures, the cylinder
liner sticks out beyond the cylinder block, so always wash
the cylinder block at a temperature of 45°C (133°F) or less.
3. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR
FLATNESS
Using a precision straight edge and feeler gauge, measure the
surface contacting the cylinder head gasket for warpage.
Maximum warpage: 0.05 mm (0.0020 in.)
If warpage is greater than maximum, replace the cylinder block.
4. INSPECT CYLINDER BORE DIAMETER
Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block.

A01168EM2548A01467
Front
Thrust
Direction
Axial
Direction
A10 mm
(0.39 in.)
B
C10 mm
(0.39 in.)
1
2
1
2
A01166
A01194
A12949
EM±72
± ENGINE MECHANICALCYLINDER BLOCK
2001 PRIUS (RM778U)
5. INSPECT CYLINDER BORE DIAMETER
Using a cylinder gauge, measure the cylinder bore diameter at
positions A, B and C in the thrust and axial directions.
Standard diameter:
75.000 ± 75.013 mm (2.95275 ± 2.95326 in.)
Maximum diameter:
75.013 mm (2.95326 in.)
If the diameter is greater than maximum, replace the cylinder
block.
6. REMOVE CYLINDER RIDGE
If the wear is less than 0.2 mm (0.008 in,), using a ridge reamer,
grind the top of the cylinder.
7. INSPECT 12 POINTED HEAD BEARING CAP SUB±
ASSEMBLY BOLTS
Using vernier calipers, measure the tension portion diameter of
the bolt.
Standard diameter: 7.3 ± 7.5 mm (0.287 ± 0.295 in.)
Minimum diameter: 7.3 mm (0.287 in.)
If the diameter is less than minimum, replace the bolt.
8. CLEAN PISTON
(a) Using a gasket scraper, remove the carbon from the pis-
ton top.

A12950
A12951
A1295227 mm
A12953
± ENGINE MECHANICALCYLINDER BLOCK
EM±73
2001 PRIUS (RM778U)
(b) Using a groove cleaning tool or broken ring, clean the pis-
ton ring grooves.
(c) Using solvent and a brush, thoroughly clean the piston.
NOTICE:
Do not use a wire brush.
9. INSPECT PISTON OIL CLEARANCE
(a) Using a micrometer, while placing the piston up side
down, take measurement at the position of 27 mm (1.06
in.).
Piston diameter:
74.930 ± 74.940 mm (2.94999 ± 2.95039 in.)
(b) Measure the cylinder bore diameter in the thrust direc-
tions. (See procedure in step 5)
(c) Subtract the piston diameter measurement from the cylin-
der bore diameter measurement.
Standard oil clearance:
0.045 ± 0.068 mm (0.00177 ± 0.00268 in.)
Maximum oil clearance:
0.095 mm (0.0037 in.)
If the oil clearance is greater than maximum, replace all the 4
pistons. If necessary, replace the cylinder block.
10. INSPECT PISTON RING END GAP
Using a feeler gauge, measure the clearance between new pis-
ton ring and the wall of the ring groove.
Ring groove clearance:
0.030 ± 0.070 mm (0.0012 ± 0.0028 in.)
If the clearance is not as specified, replace the piston.