engine TOYOTA PRIUS 2001 Service Repair Manual

PP2FD±02
PP±6
± PREPARATIONENGINE MECHANICAL
2001 PRIUS (RM778U)
SSM (Special Service Materials)
08826±00080Seal Packing Black or equivalent
(FIPG)
08826±00100Seal Packing 1282B,
THREE BOND 1282B or equivalent
(FIPG)
08833±00070Adhesive 1324,
THREE BOND 1324 or equivalent

PP2FQ±02
± PREPARATIONSFI
PP±9
2001 PRIUS (RM778U)
RECOMMENDED TOOLS
09082±00040TOYOTA Electrical Tester.
09200±00010Engine Adjust Kit .
09258±00030Hose Plug Set .Plug for the vacumm hose, fuel hose
etc.

PP2FI±03
PP±14
± PREPARATIONCOOLING
2001 PRIUS (RM778U)
COOLANT
ItemCapacityClassification
Engine coolant4.9 liters (5.2 US qts, 4.3 lmp. qts)Ethylene±glycol base

PP2FL±03
± PREPARATIONLUBRICATION
PP±17
2001 PRIUS (RM778U)
LUBRICANT
ItemCapacityClassification
Engine oil
Drain and refill w/ Oil filter change
w/o Oil filter change
Dry fill
3.7 liters (3.9 US qts, 3.3 lmp.qts)
3.4 liters (3.6 US qts, 3.0 lmp.qts)
4.1 liters (4.3 US qts, 3.6 lmp.qts)API grade SJ, Energy±Conserving or ILSAC mul-
tigrade engine oil. SAE 5W±30 is the best choice
for your vehicle, for good fuel economy,and good
starting in cold weather.

PP2FN±02
± PREPARATIONIGNITION
PP±19
80 Author: Date:
2001 PRIUS (RM778U)
IGNITION
RECOMMENDED TOOLS
09082±00040TOYOTA Electrical Tester.
09200±00010Engine Adjust Kit .

PP3AN±01
PP±26
± PREPARATIONHYBRID TRANSAXLE
2001 PRIUS (RM778U)
RECOMMENDED TOOLS
09025±00010Torque Wrench (30 kgf±cm)
09031±00030Pin Punch .
09040±00011Hexagon Wrench Set .
09082±00040TOYOTA Electrical Tester.
09090±04020Engine Sling Device

SS174±03
SS±6
± SERVICE SPECIFICATIONSENGINE MECHANICAL
128 Author: Date:
2001 PRIUS (RM778U)
ENGINE MECHANICAL
SERVICE DATA
Compression
pressureat 250 rpm STD
Minimum
Difference between each cylinder728 kPa (7.4 kgf/cm2, 106 psi)
534 kPa (5.4 kgf/cm2, 77 psi)
98 kPa (1.0 kgf/cm2, 14 psi)
Valve
clearance
at cold Intake
Exhaust
Valve lifter for repair part No. 06
No. 08
No. 10
No. 12
No. 14
No. 16
No. 18
No. 20
No. 22
No. 24
No. 26
No. 28
No. 30
No. 32
No. 34
No. 36
No. 38
No. 40
No. 42
No. 44
No. 46
No. 48
No. 50
No. 52
No. 54
No, 56
No. 58
No. 60
No. 62
No. 64
No. 66
No. 68
No. 70
No. 72
No. 740.17 ± 0.23 mm (0.007 ± 0.009 in.)
0.27 ± 0.33 mm (0.011 ± 0.013 in.)
5.060 mm (0.1992 in.)
5.080 mm (0.2000 in.)
5.100 mm (0.2008 in.)
5.120 mm (0.2016 in.)
5.140 mm (0.2024 in.)
5.160 mm (0.2031 in.)
5.180 mm (0.2039 in.)
5.200 mm (0.2047 in.)
5.220 mm (0.2055 in.)
5.240 mm (0.2063 in.)
5.260 mm (0.2071 in.)
5.280 mm (0.2079 in.)
5.300 mm (0.2087 in.)
5.320 mm (0.2094 in.)
5.340 mm (0.2102 in.)
5.360 mm (0.2110 in.)
5.380 mm (0.2118 in.)
5.400 mm (0.2126 in.)
5.420 mm (0.2134 in.)
5.440 mm (0.2142 in.)
5.460 mm (0.2150 in.)
5.480 mm (0.2157 in.)
5.500 mm (0.2165 in.)
5.520 mm (0.2173 in.)
5.540 mm (0.2181 in.)
5.560 mm (0.2189 in.)
5.580 mm (0.2197 in.)
5.600 mm (0.2205 in.)
5.620 mm (0.2213 in.)
5.640 mm (0.2220 in.)
5.660 mm (0.2228 in.)
5.680 mm (0.2236 in.)
5.700 mm (0.2244 in.)
5.720 mm (0.2252 in.)
5.740 mm (0.2260 in.)
Ignition timing7 ± 15° BTDC @ idle
Idle speedw/ Cooling fan off1,000 ± 50 rpm (A/C OFF)
1,200 ± 50 rpm (A/C ON)
Chain and
timing sprocketChain length at 16 linksMaximum
Camshaft timing sprocket wear (w/ chain) Minimum
Crankshaft timing sprocket wear (w/ chain) Minimum123.2 mm (4.850 in.)
96.2 mm (3.787 in.)
50.5 mm (1.988 in.)
Chain
tensioner
slipper and
vibration
damperWear Maximum1.0 mm (0.039 in.)

± 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.)

SS±8
± SERVICE SPECIFICATIONSENGINE MECHANICAL
130 Author: Date:
2001 PRIUS (RM778U) Cylinder
block
Cylinder head surface warpage Maximum
Cylinder bore diameter STD
Maximum
Main journal bore diameter Mark 0
Mark 1
mark 2
Mark 3
Mark 4
Mark 5
Mark 6
12 pointed head bearing cap sub±assembly bolt diameter
at tension portion STD
Minimum0.05 mm (0.0020 in.)
75.000 ± 75.013 mm (2.95275 ± 2.95326 in.)
75.013 mm (2.95326 in.)
50.000 ± 50.003 mm (1.96850 ± 1.96862 in.)
50.003 ± 50.005 mm (1.96862 ± 1.96870 in.)
50.005 ± 50.007 mm (1.96870 ± 1.96878 in.)
50.007 ± 50.010 mm (1.96878 ± 1.96889 in.)
50.010 ± 50.012 mm (1.96889 ± 1.96897 in.)
50.012 ± 50.014 mm (1.96897 ± 1.96905 in.)
50.014 ± 50.016 mm (1.96905 ± 1.96913 in.)
7.3 ± 7.5 mm (0.287 ± 0.295 in.)
7.3 mm (0.287 in.)
Piston and
Piston ring
Piston diameter
at 27 mm (1.063 in.) from the piston head
Piston oil clearance STD
Maximum
Piston ring groove clearance
Piston ring end gap
STD No. 1
No. 2
Oil
Maximum No. 1
No. 2
Oil
74.945 ± 74.955 mm (2.95058 ± 2.95098 in.)
0.045 ± 0.068 mm (0.00177 ± 0.00268 in.)
0.08 mm (0.0031 in.)
0.030 ± 0.070 mm (0.0012 ± 0.0028 in.)
0.22 ± 0.32 mm (0.0087 ± 0.0126 in.)
0.32 ± 0.47 mm (0.0126 ± 0.0185 in.)
0.15 ± 0.45 mm (0.0059 ± 0.0177 in.)
0.88 mm (0.0346 in.)
1.03 mm (0.0406 in.)
0.92 mm (0.0362 in.)
Connecting
rod
Thrust clearance STD
Maximum
Connecting rod thickness
Connecting rod bearing center wall thickness
Reference Mark 1
Mark 2
Mark 3
Connecting rod oil clearance STD
Maximum
Rod out±of±alignment Maximum per 100 mm (3.94 in.)
Rod twist Maximum per 100 mm (3.94 in.)
Bushing inside diameter
Piston pin diameter
Bushing oil clearance STD
Maximum
Connecting rod bolt diameter
at tension portion STD
Minimum0.16 ± 0.36 mm (0.0063 ± 0.0142 in.)
0.36 mm (0.0142 in.)
19.788 ± 19.840 mm (0.779 ± 0.781 in.)
1.488 ± 1.492 mm (0.0586 ± 0.0587 in.)
1.492 ± 1.496 mm (0.0587 ± 0.0589 in.)
1.496 ± 1.500 mm (0.0589 ± 0.0591 in.)
0.016 ± 0.040 mm (0.0006 ± 0.0016 in.)
0.06 mm (0.0024 in.)
0.05 mm (0.0020 in.)
0.05 mm (0.0020 in.)
18.010 ± 18.019 mm (0.7091 ± 0.7094 in.)
17.988 ± 18.007 mm (0.7086 ± 0.7089 in.)
0.009 ± 0.015 mm (0.0003 ± 0.0006 in.)
0.05 mm (0.0020 in.)
6.6 ± 6.7 mm (0.260 ± 0.264 in.)
6.4 mm (0.252 in.)

± SERVICE SPECIFICATIONSENGINE MECHANICAL
SS±9
131 Author: Date:
2001 PRIUS (RM778U) Crankshaft
Thrust clearance STD
Maximum
Thrust washer thickness
Main journal oil clearance STD
Maximum
Main journal diameter
Reference Mark 0
Mark 1
Mark 2
Mark 3
Mark 4
Mark 5
Main bearing center wall thickness
Reference Mark 1
Mark 2
Mark 3
Mark 4
Crank pin diameter
Circle run out Maximum
Main journal taper and out±of roundMaximum
Crank pin taper and out±of roundMaximum0.090 ± 0.190 mm (0.00354 ± 0.00748 in.)
0.30 mm (0.012 in.)
2.430 ± 2.480 mm (0.09567 ± 0.09764 in.)
0.010 ± 0.023 mm (0.0004 ± 0.0009 in.)
0.07 mm (0.0028 in.)
45.988 ± 45.990 mm (1.81054 ± 1.81062 in.)
45.990 ± 45.992 mm (1.81062 ± 1.81071 in.)
45.992 ± 45.994 mm (1.81071 ± 1.81078 in.)
45.994 ± 45.996 mm (1.81078 ± 1.81086 in.)
45.996 ± 45.998 mm (1.81086 ± 1.81094 in.)
45.998 ± 46.000 mm (1.81094 ± 1.81102 in.)
1.992 ± 1.995 mm (0.07843 ± 0.07854 in.)
1.995 ± 1.998 mm (0.07854 ± 0.07866 in.)
1.998 ± 2.001 mm (0.07866 ± 0.07878 in.)
2.001 ± 2.004 mm (0.07878 ± 0.07890 in.)
39.992 ± 40.000 mm (1.5745 ± 1.5748 in.)
0.03 mm (0.0012 in.)
0.02 mm (0.0008 in.)
0.02 mm (0.0008 in.)