TOYOTA PRIUS 2001 Service Repair Manual

A12954
11 0
mm
EM7639
Z00064
Z00065
A01185
EM±74
± ENGINE MECHANICALCYLINDER BLOCK
2001 PRIUS (RM778U)
11. INSPECT PISTON RING END GAP
(a) Insert the piston ring into the cylinder bore.
(b) Using a piston, push the piston ring a little beyond the bot-
tom of the ring travel, 110 mm (4.33 in.) from the top of the
cylinder block.
(c) Using a feeler gauge, measure the end gap.
Standard end gap:
No. 1 0.22 ± 0.32 mm (0.0087 ± 0.0126 in.)
No. 2 0.32 ± 0.47 mm (0.0126 ± 0.0185 in.)
Oil (Side rail) 0.15 ± 0.45 mm (0.0059 ± 0.0177 in.)
Maximum end gap:
No. 1 0.88 mm (0.0346 in.)
No. 2 1.03 mm (0.0406 in.)
Oil 0.92 mm (0.0362 in.)
If the end gap is greater than maximum, replace the piston ring.
If the end gap is greater than maximum, even with a new piston
ring, replace the cylinder block.
12. INSPECT CONNECTING ROD ALIGNMENT
Using a rod aligner and feeler gauge, check the connecting rod
alignment.

Check for out±of±alignment
Maximum out±of alignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If out±of alignment is greater than maximum, replace the con-
necting rod assembly.

Check for twist
Maximum twist:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod as-
sembly.
13. INSPECT PISTON PIN OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the
connecting rod bushing.
Bushing inside diameter:
18.010 ± 18.019 mm (0.7091 ± 0.7094 in.)

EM0227
A01470
A11241
± ENGINE MECHANICALCYLINDER BLOCK
EM±75
2001 PRIUS (RM778U)
(b) Using a micrometer, measure the piston pin diameter.
Piston pin diameter:
17.988 ± 18.007 mm (0.7086 ± 0.7089 in.)
(c) Subtract the piston pin diameter measurement from the
bushing inside diameter measurement.
Standard oil clearance:
0.009 ± 0.015 mm (0.0003 ± 0.0006 in.)
Maximum oil clearance:
0.05 mm (0.0020 in.)
If the oil clearance is greater than maximum, replace the con-
necting rod. If necessary, replace the piston and piston pin as
a set.
14. INSPECT CONNECTING ROD BOLTS
Using a vernier calipers, measure the tension portion diameter
of the bolt.
Standard diameter: 6.6 ± 6.7 mm (0.260 ± 0.264 in.)
Minimum diameter: 6.4 mm (0.252 in.)
If the diameter is less than minimum, replace the bolt.
15. INSPECT CRANKSHAFT FOR CIRCLE RUNOUT
(a) Place the crankshaft on V±blocks.
(b) Using a dial indicator, measure the circle runout, as
shown in the illustration.
Maximum circle runout: 0.03 mm (0.0012 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.

A11242
EM±76
± ENGINE MECHANICALCYLINDER BLOCK
2001 PRIUS (RM778U)
16. INSPECT MAIN JOURNALS AND CRANK PINS
(a) Using a micrometer, measure the diameter of each main
journal and crank pin.
Main journal diameter:
45.988 ± 46.000 mm (1.81054 ± 1.81102 in.)
Crank pin diameter:
39.992 ± 40.000 mm (1.5745 ± 1.5748 in.)
If the diameter is not as specified, check the oil clearance.
(See page EM±64)
If necessary, replace the crankshaft.
(b) Check each main journal and crank pin for taper and out±
of±round as shown.
Maximum taper and out±of±round:
0.02 mm (0.0008 in.)
If the taper and out±of round is greater than maximum, replace
the crankshaft.

EM1J4±02
A12957
(Cavity)
(Protrusion)Front Mark
SST
SST SST
A12958
No. 2
A12959
Oil Ring
(Expander)
No. 2 CompressionOil Ring (Rail)
No. 1 Compression
Front EM±78
± ENGINE MECHANICALCYLINDER BLOCK
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 all gaskets, O±rings and oil seals with new parts.
1. ASSEMBLE PISTON AND CONNECTING ROD
(a) Gradually heat the piston side of connecting rod to 80 ±
90°C (176 ± 194°F).
(b) Coat the piston pin and pin holes of the piston with engine
oil.
(c) Align the cavity on the piston with the protrusion on the
connecting rod.
(d) Using SST, press in the piston pin.
SST 09221±25026 (09221±00021, 09221±00030,
09221±00190, 09221±00141, 09221±00150)
2. INSTALL PISTON RINGS
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings.
(c) Position the piston rings so that the ring ends are as
shown.
NOTICE:
Do not align the ring ends.

A01190
A10470
Block
Side:Cap
Side:
ABCD
A10459
1
24
35
6
7
8
9
10
± ENGINE MECHANICALCYLINDER BLOCK
EM±79
2001 PRIUS (RM778U)
3. Supply parts:
INSTALL MAIN BEARINGS
HINT:
Upper bearings have an oil groove and oil holes; Lower bear-
ings do not.
(a) Align the bearing claw with the claw groove of the cylinder
block, and push in the 5 upper bearings.
NOTICE:
Install the bearing with the oil hole in the cylinder block.
(b) Align the bearing claw with the claw grove of the main
bearing cap, and push in the 5 lower bearings.
4. Manufacture parts:
INSTALL MAIN BEARINGS
HINT:
Upper bearings have an oil groove and oil holes; Lower bear-
ings do not.
Measure the clearance on both sides of the bearing and install
it so that the difference between measured values will be within
the specified bellow.
Specified clearance:
A ± B = 0.8 mm (0.032 in.)
C ± D = 0.4 mm (0.016 in.)
5. PLACE CRANKSHAFT ON CYLINDER BLOCK
6. INSTALL BEARING CAPS
(a) Install the 5 bearing caps.
HINT:
Each bearing cap has a number and front mark.
(b) Apply a light coat of engine oil on the threads and under
the head of the bearing cap bolts.

A01205
A10456
EM±80
± ENGINE MECHANICALCYLINDER BLOCK
2001 PRIUS (RM778U)
(c) Install and uniformly tighten the 10 bolts of the bearing
cap is several passes, in the sequence shown.
Torque:
1ST 22 N´m (220 kgf´cm, 16 ft´lbf)
2ND Turn 90 °
(d) Check that the crankshaft turns smoothly.
7. CHECK CRANKSHAFT THRUST CLEARANCE
(See page EM±64)
8. INSTALL PISTON AND CONNECTING ROD
ASSEMBLES
Using a piston ring compressor, push the correctly numbered
piston and connecting rod assemblies into each cylinder with
the front mark of the piston facing forward.
9. PLACE CONNECTING ROD CAP ON CONNECTING
ROD
(a) Match the numbered connecting rod cap with the con-
necting rod.
(b) Align the pin dowels of the connecting rod cap with the
pins of the connecting rod, and install the connecting rod.
(c) Check that the protrusion of the connecting rod cap is fac-
ing in the correct direction.
10. INSTALL CONNECTING ROD CAP BOLTS
HINT:

The connecting rod cap bolts are tightened in 2 progres-
sive steps (steps (b) and (d)).

If any of the connecting rod cap bolts is broken or de-
formed, replace it.
(a) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(b) Install and alternately tighten the 2 connecting rod cap
bolts in several passes.
Torque:
1ST 15 N´m (150 kgf´cm, 11 ft´lbf)
2ND Turn 90 °
If any of the connecting rod cap bolts does not meet the torque
specification, replace the connecting rod cap bolts.
11. CHECK CONNECTING ROD THRUST CLEARANCE
(See page EM±64)

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.

A14342
A10465Seal Width 2.5 ± 3.5 mm
A11269
EM±82
± ENGINE MECHANICALCYLINDER BLOCK
2001 PRIUS (RM778U)
14. INSTALL OIL STRAINER
Install a new gasket, and oil strainer with the bolt and 2 nuts.
Torque: 11 N´m (112 kgf´cm, 8 ft´lbf)
15. INSTALL OIL PAN
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surface of the main bear-
ing cap and oil pan.

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.
NOTICE:
Do not use a solvent which will affect the painted surfaces.
(b) Apply seal packing to the oil pan as shown in the illustra-
tion.
Seal packing:
Part No. 08826±00080 or equivalent

Install a nozzle that has been cut to a 2.5 ± 3.5 mm
(0.098 ± 0.138 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 the oil pan with the 9 bolts and 2 nuts. Uniformly
tighten the bolts and nuts in several passes.
Torque: 9.0 N´m (92 kgf´cm, 80 in.´lbf)
16. INSTALL OIL FILTER UNION
Torque: 30 N´m (306 kgf´cm, 21 ft´lbf)
17. INSTALL OIL FILTER
(See page LU±3)

P12477
Adhesive
A10451
± ENGINE MECHANICALCYLINDER BLOCK
EM±83
2001 PRIUS (RM778U)
18. INSTALL ENGINE COOLANT DRAIN UNION
(a) Apply adhesive to 2 or 3 threads.
Adhesive:
Part No. 08833±00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Install the drain union.
Torque: 35 N´m (350 kgf´cm, 25 ft´lbf)
HINT:
After applying the specified torque, rotate the drain union clock-
wise until its drain port is facing downward.
19. INSTALL KNOCK SENSOR
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
20. INSTALL OIL PRESSURE SWITCH
(See page LU±1)
21. INSTALL THERMOSTAT
(See page CO±12)
22. INSTALL WATER BYPASS PIPE
Torque: 9.0 N´m (92 kgf´cm, 80 in.´lbf)
23. INSTALL ENGINE WIRE
24. INSTALL CYLINDER HEAD
(See page EM±45)
25. INSTALL TIMING SPROCKETS AND TIMING CHAIN
(See page EM±21)
26. REMOVE ENGINE STAND

EC0HT±01
B11797
Charcoal Canister VSV for EVAP
Heated Oxygen Sensor
(Bank 1 Sensor 1)
Heated Oxygen Sensor
(Bank 1 Sensor 2) Fuel Tank
Air Cleaner
Throttle Valve
Pressure Sensor
for HCAC
Check
Valve VSV for HCAC
Actuator for HCAC
Refer to next page
± EMISSION CONTROLPARTS LAYOUT AND SCHEMATIC DRAWING
EC±3
2001 PRIUS (RM778U)
DRAWING