oil pump TOYOTA PRIUS 2001 Service Owner's Manual

SS179±02
± SERVICE SPECIFICATIONSLUBRICATION
SS±17
2001 PRIUS (RM778U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Oil pressure switch x Cylinder block131309
Oil drain plug x Oil pan3838728
Plug x Oil pump body2525518
Oil pump cover x Timing chain cover Bolt
Screw8.8
10.390
10578 in.´lbf
8

SS1HF±01
± SERVICE SPECIFICATIONSHYBRID TRANSAXLE
SS±25
2001 PRIUS (RM778U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Oil pump cover x MG2 assembly5.55649 in.´lbf
Transaxle oil drain plug4949836
Hybrid transaxle assembly x Engine3333224
Coolant drain plug x MG1 assembly3940029
Screw plug x MG1 assembly12.71309
Screw plug x MG2 assembly24.525018
Filler plug x MG2 assembly3940029
MG1 assembly x MG2 assembly2525018
Sleeve bracket x MG1 assembly131309
Lock clamp x MG1 assembly5.45548 in.´lbf
Oil strainer x MG2 assembly5.55649 in.´lbf
Oil pan x MG2 assembly7.67767 in.´lbf
Parking shaft cover x MG2 assembly1313010
Motor water jacket cover x MG2 assembly5.55649
Housing tube x MG1 assembly1515211
Detent spring set bolt101007
Parking cover x MG2 assembly5.55649 in.´lbf
Oil pump cover x plug7.357565 in.´lbf
Wiring harness connector x MG2 assembly5.55649 in.´lbf
Wiring harness connector x MG1 assembly5.55649 in.´lbf
Water jacket union5051037
High±voltage cable set bolt (3 under power cable cover)1818313
High±voltage cable set bolt (3 outside)5.55649 in.´lbf
Power cable cover x MG1 assembly4.84842 in.´lbf
Mounting bracket x MG2 assembly5253038
Shift lever assembly x Steering column88071 in.´lbf
Differential case x Ring gear879064

A04438A13924A14466
TC
CG
A14060
DI±10
± DIAGNOSTICSENGINE
2001 PRIUS (RM778U)
5 Check ignition timing.
PREPARATION:
(a) Warm up engine to normal operating temperature.
(b) Shift transmission into P position.
(c) Keep the engine speed at idle.
(d) Using SST, connect terminals TE1 and E1 of DLC1.
SST 09843±18020
(e) Using a timing light, connect the tester to the ignition coil
connector wire (See page EM±11).
(f) Transit to inspection mode.
CHECK:
Check ignition timing.
OK:
Ignition timing: 7 ± 15° BTDC at idle
NG Proceed to page IG±1 and continue to trouble-
shoot.
OK
Proceed to problem symptoms table on page
DI±22.
6 Check fuel pressure.
PREPARATION:
(a) Be sure that enough fuel is in the tank.
(b) Connect the TOYOTA hand±held tester to the DLC3.
(c) Turn the ignition switch ON and push the TOYOTA hand±
held tester main switch ON.
(d) Use the ACTIVE TEST mode to operate the fuel pump.
(e) Please refer to the TOYOTA hand±held tester operator's
manual for further details.
(f) If you have no TOYOTA hand±held tester, connect the
positive (+) and negative (±) leads from the battery to the
fuel pump connector (See page SF±6).
CHECK:
Check for fuel pressure in the fuel inlet hose when it is pinched
off.
HINT:
At this time, you will hear a fuel flowing noise.

± DIAGNOSTICSANTI±LOCK BRAKE SYSTEM WITH EBD & RBS
DI±421
2001 PRIUS (RM778U)
DTC C1253/53 Hydro Motor Relay Circuit
CIRCUIT DESCRIPTION
The hydro motor relay supplies power to the hydraulic brake booster pump motor. While the ABS & EBD &
RBS are activated, the ECU switches the motor relay ON and operates the hydraulic brake booster pump
motor.
DTC No.DTC Detecting ConditionTrouble Area
C1253/53
When any of the following 1. through 4. is detected:
1. After turning the ignition switch ON, open in the relay
coil is detected for more than 1 sec.
2. When the pressure switch does not control motor
driving, the status that the motor relay is always ON
continues for more than 1 sec. due to short circuit.
3. When the pressure switch (PH) detects the low
pressure or while the pump motor operates to increase
the pressure, the status that the motor relay does not
turn ON continues for more than 0.2 sec.
4. When pressure switch does not control motor driving,
the status that the motor relay is always ON due to the
welded contact continues for more than 2 sec.

Hydro motor relay

Hydro motor relay circuit
DI29A±13

A13926
N´m (kgf´cm, ft´lbf)

Non±reusable part: Specified torque RH Engine Mounting Bracket
Timing Chain Cover
Cylinder Head CoverIgnition Ciol
(w/ Igniter)
PCV Hose
Front Crankshaft
Oil Seal Crankshaft Pulley
Gasket
Water Pump Pulley
Water Pump
GasketChain Tensioner
Slipper
Chain Vibration Damper Tinming Chain
Timing Chain
TensionerPin




O±Ring


O±Ring

11 (110, 8)
15 (150, 11)
128 (1,300, 94)
55 (561, 41)
10 (100, 7)
EM±14
± ENGINE MECHANICALTIMING CHAIN
1130 Author: Date:
2001 PRIUS (RM778U)

A11245
Timing Marks
A11253
SST
SST
A11254
SST
A11258
A11255
± ENGINE MECHANICALTIMING CHAIN
EM±17
2001 PRIUS (RM778U)
(b) Check that both timing marks on the camshaft timing
sprocket and valve timing controller assembly are facing
right up as shown in the illustration.
If not, turn the crankshaft 1 revolution (360°) and align the
marks as above.
16. REMOVE CRANKSHAFT PULLEY
(a) Using SST, remove the pulley bolt.
SST 09213±70010, 09330±00021
(b) Remove the crankshaft pulley and pin.
HINT:
If necessary, remove the pulley with SST.
SST 09950±50012 (09951±05010, 09952±05010,
09953±05020, 09954±05020)
17. REMOVE CRANKSHAFT POSITION SENSOR
(See page IG±12)
18. REMOVE RH ENGINE MOUNTING BRACKET
Remove the 4 bolts and mounting bracket.
19. REMOVE WATER PUMP (See page CO±6)
20. REMOVE OIL CONTROL VALVE (See page EM±29)
21. REMOVE TIMING CHAIN COVER
(a) Remove the 13 bolts and nut.
(b) Using a torx wrench socket (E8), remove the stud bolt.
(c) Remove the timing chain cover by prying the portions be-
tween the cylinder head and cylinder block with a screw-
driver.
NOTICE:
Be careful not to damage the contact surfaces of the timing
chain cover, cylinder head and cylinder block.

A11260
Seal Width:
4 ± 5 mmFIPG
FIPG
A11261
Seal
Packing
Seal
Packing
Seal Width
4 ± 5 mm EM±22
± ENGINE MECHANICALTIMING CHAIN
2001 PRIUS (RM778U)
3. INSTALL TIMING CHAIN COVER AND WATER PUMP
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the timing
chain cover, cylinder head and cylinder block.

Using a razor blade and a gasket scraper, remove
all the old packing (FIPG) material from the gasket
surfaces 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 timing chain cover as shown in
the illustration.
Seal packing:
Part No. 08826 ± 00100 or equivalent

Install a nozzle that has been cut to a 4 ± 5 mm (0.16
± 0.20 in.) opening.

FIPG shall be accumulated in the groove for FIPG
to a depth of 2.5 mm (0.10 in.) or more.
HINT:
Avoid applying an excessive amount to the surface.

Parts must be assembled within 3 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(c) Apply seal packing to 4 locations as shown in the illustra-
tion.
Seal packing:
Part No. 08826 ± 00080 or equivalent

Install a nozzle that has been cut to a 4 ± 5 mm (0.16
± 0.20 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 removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(d) Install 2 new O±rings to the cylinder block and oil pan No.
1.

A11274
A B
CE D
F
AG
G
EB
A
AA
A11258
A
B
± ENGINE MECHANICALTIMING CHAIN
EM±23
2001 PRIUS (RM778U)
(e) Install the timing chain cover, new O±ring and water pump
with the 16 bolts and 3 nuts. Uniformly tighten the bolts
and nut in several passes.
Torque:
Bolt A 11 N´m (113 kgf´cm, 8 ft´lbf)
Bolt B 24 N´m (245 kgf´cm, 18 ft´lbf)
Bolt C 11 N´m (113 kgf´cm, 8 ft´lbf)
Bolt D 24 N´m (245 kgf´cm, 18 ft´lbf)
Bolt E 11 N´m (113 kgf´cm, 8 ft´lbf)
Nut F 24 N´m (245 kgf´cm, 18 ft´lbf)
Nut G 11 N´m (113 kgf´cm, 8 ft´lbf)
NOTICE:

Pay attention not to wrap the chain and slipper over
the chain cover seal line.

After installing the chain cover, must install the
mounting bracket and water pump within 15 minutes.
HINT:
Each bolt length in indicated in the illustration.
A 20 mm (0.787 in.)
B 30 mm (1.181 in.)
C 35 mm (1.378 in.)
D 20 mm (0.787 in.)
E 35 mm (1.378 in.)
4. INSTALL RH ENGINE MOUNTING BRACKET
(a) Apply seal packing to threads of the mounting bolt.
Seal packing:
Part No. 08826 ± 00080 or equivalent
HINT:
Do not apply seal packing to 2 or 3 threads of the bolt end.
(b) Install the mounting bracket with the 4 bolts.
Torque: 55 N´m (561 kgf´cm, 41 ft´lbf)
5. INSTALL CRANKSHAFT POSITION SENSOR
Torque:
Bolt A 7.5 N´m (76 kgf´cm, 66 in.´lbf)
Bolt B 11 N´m (113 kgf´cm, 8 ft´lbf)
6. INSTALL OIL CONTROL VALVE (See page EM±45)
Torque: 7.5 N´m (76 kgf´cm, 66 in.´lbf)

A13931
N´m (kgf´cm, ft´lbf)

Non±reusable part: Specified torque RH Engine Mounting Bracket
Timing Chain CoverCylinder Head Cover
PCV Hose
Front Crankshaft
Oil SealGasket
Water Pump Pulley
Water Pump
O±Ring
Chain Tensioner
Slipper
Chain Vibration Damper Timing Chain
Timing Chain
Tensioner Pin




Crankshaft Pulley
Gasket
Valve Lifter
Keeper Spring Retainer
Valve Spring
Oil Seal Spring Seat
Valve Guide
Bushing
No. 1 Camshaft
Bearing Cap
Valve Timing
Controller AssemblyValve
Cylinder Head
Camshaft Timing
SprocketNo. 2 Camshaft
Bearing Cap



Gasket
O±Ring


55 (561, 41)
128 (1,300, 94)
15 (150, 11)
11 (110, 8)
Injector
1st:
2nd: 90°
3rd: 90°
See page EM±4529.4 (300, 22)
10 (100, 7)
64 (652, 47)
EM±28
± ENGINE MECHANICALCYLINDER HEAD
1144 Author: Date:
2001 PRIUS (RM778U)

B11830
A13909
F12396
TOYOTA Hand±Held Tester
DLC3
± SFISFI SYSTEM
SF±5
1219 Author: Date:
2001 PRIUS (RM778U)
(4) Match the axis of the connector with axis of the pipe,
and push in the connector until retainer makes a
ºclickº sound. In case that the connections is tight,
apply little amount of new engine oil on the tip of the
pipe.
(5) After having finished the connection, check if the
pipe and the connector are securely connected by
pulling them.
(6) Check if there is any fuel leakage.
(g) Observer these precautions when handling nylon tube.
(1) Pay attention not to turn the connected part of the
nylon tube and the quick connector with force when
connecting them.
(2) Pay attention not to kink the nylon tube.
(3) Do not remove the nylon tube.
(4) Must not close the piping with the nylon tube by
bending it.
(h) Check that there are no fuel leaks after doing mainte-
nance anywhere on the fuel system.
(1) Connect the TOYOTA hand±held tester to the
DLC3.
(2) Turn the ignition switch ON and push TOYOTA
hand±held tester main switch ON.
(3) Select the active test mode on the TOYOTA hand±
held tester.
(4) Please refer to the TOYOTA hand±held tester oper-
ator 's manual for further details.
(5) If you have no TOYOTA hand±held tester, connect
the positive (+) and negative (±) leads from the bat-
tery to the fuel pump connector.
(See page SF±6)
(6) Check that there are no leaks from any part of the
fuel system.
(7) Turn the ignition switch to LOCK.
(8) Disconnect the TOYOTA hand±held tester from the
DLC3.