cylinder bolt TOYOTA PRIUS 2001 Service Owner's Manual

A13939
I18009
A13909
A13938
EM±60
± ENGINE MECHANICALENGINE UNIT
2001 PRIUS (RM778U)
12. INSTALL EXHAUST PIPE
(a) Install the 2 gaskets to the exhaust pipe and connect the
2 O±rings.
(b) Install the 2 springs and 3 bolts.
Torque:
Front exhaust pipe: 62 N´m (630 kgf´cm, 46 ft´lbf)
Tailpipe: 32 N´m (326 kgf´cm, 24 ft´lbf)
(c) Connect the hose to the actuator.
(d) Connect the heated oxygen sensor.
13. INSTALL A/C COMPRESSER
(a) Connect the A/C compresser to the engine with the 4
bolts.
Torque: 25 N´m (255 kgf´cm, 18 ft´lbf)
(b) Connect the A/C compresser connector.
14. CONNECT INTERMEDIATE EXTENSION STEERING
ASSEMBLY (See page SR±14)
15. INSTALL DRIVE BELT (See page SA±23)
16. CONNECT FUEL TUBE
17. INSTALL J/B NO. 1 TO RH FENDER APRON
18. CONNECT ENGINE WIRE TO CABIN
(a) Pull in the engine wire to the cowk panel and connect the
grommet.
(b) Connect the ECM connectors.
(c) Install the ECM (See page SF±63).
19. INSTALL BRAKE RESERVOIR TANK
(a) Install the reservoir tank with the 2 bolts.
(b) Connect the brake fluid level sensor connector.
20. CONNECT SHIFT LEVER CABLE TO TRANSAXLE
21. CONNECT HEATER HOSE TO CYLINDER BLOCK
22. CONNECT 2 RADIATOR HOSES TO RADIATOR
23. INSTALL ENGINE COOLANT RESERVOIR TANK
24. INSTALL AIR INLET

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.

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.

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.

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.