radiator TOYOTA PRIUS 2001 Service Owner's Guide

I18401
A/C Amplifier
CF Engine Room J/B
Fan No.2 Relay
A9
A91
2RF IE16
R±W R±W
1J
1A
1J
1K
1J
1K
1B
1J
1K 1K 10
11
5
3
12
5
2
3
4
7 Fan No.1 Relay
Fan No.1 Relay1
2
5 3
4
1
2
5
3
3 5
12
CDS FAN
RDIV±YJ27
J28J27 EE
E J/C L±W To Engine ECU
W±B
V±Y
From
DC/DC Fuse
From ECU±
IG Fuse 1
1 2 R1 Radiator Fan Motor
W4 Water Temp. Switch12
W±B
W±BA3 A/C Pressure Switch2 3
J1
J/CJ7
J/C
AA A
AW±BW±B
IEV±Y
A1
A/C Condenser
Fan Motor
G±W
W±G
W
L±W2
W±B W±B
± DIAGNOSTICSAIR CONDITIONING SYSTEM
DI±953
2001 PRIUS (RM778U)
WIRING DIAGRAM

A12943
1
2973
4
3
368
5
A11228
1
23
45
67
8
9
10
A12944
± ENGINE MECHANICALCYLINDER HEAD
EM±31
2001 PRIUS (RM778U)

Do not disassembly the valve timing controller as-
sembly.
25. REMOVE CAMSHAFTS
Uniformly loosen and remove the 19 bearing cap bolts, in sever-
al passes, in the sequence shown, and remove the 9 bearing
caps, intake and exhaust camshafts.
26. REMOVE CYLINDER HEAD
(a) Disconnect the upper radiator hose from the water hose
union
(b) Disconnect the heater water hose from the water hose
union
(c) Using a 8 mm bi±hexagon wrench, uniformly loosen and
remove the 10 cylinder head bolts, in several passes, in
the sequence shown. Remove the 10 cylinder head bolts
and plate washers.
NOTICE:
Head warpage or cracking could result from removing
bolts in an incorrect order.
(d) Remove the bolt holding the water bypass pipe to the cyl-
inder head.
(e) Lift the cylinder head from the dowels on the cylinder
block and replace the cylinder head on wooden blocks on
a bench.
HINT:
If the cylinder head is difficult to lift off, pry between the cylinder
head and cylinder block with a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.

EM16M±02
A11230
For Radiator Hose
For Water Bypass Hose 15 mm18 mm
A11231
Adhesive
A11232
AB
A01063
SST
± ENGINE MECHANICALCYLINDER HEAD
EM±43
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 oil seals with new ones.
1. INSTALL WATER HOSE UNIONS
HINT:
When using a new cylinder head, water hose unions must be
installed.
(a) Mark the standard position away from the edge, onto the
water hose union.
(b) Apply adhesive to the water hose union hole of the cylin-
der head.
Adhesive:
Part No.08833±00070, THREE BOND 1324 or
equivalent
(c) Using a press, press in a new water hose union until there
is protruding from the cylinder head.
Standard protrusion:
A 29 mm (1.14 in.)
B 44 mm (1.73 in.)
NOTICE:
Avoid pressing a new water hose union in too far by mea-
suring the amount of protrusion while pressing.
2. INSTALL VALVES
(a) Using SST, push in a new oil seal.
SST 09201±41020

A12945
No.1 Cam Lobe
A12946
A12943
9
9
96
5
2
1
4
3
8
7 EM±46
± ENGINE MECHANICALCYLINDER HEAD
2001 PRIUS (RM778U)
(g) Connect the upper radiator hose to the water hose
unions.
(h) Connect the heater hose to the water hose unions.
3. INSTALL CAMSHAFTS
(a) Place the 2 camshafts on the cylinder head with the No.1
cam lobes facing as shown the illustration.
(b) Install the bearing caps in their proper locations.
HINT:
No. 2 camshaft bearing cap has a number and front mark.
(c) Apply a light coat of engine oil on the threads and under
the heads of the bearing cap bolts.
(d) Install and uniformly tighten the 19 bearing cap bolts.
After tightening the No.1 camshaft bearing cap, tighten
then in several passes, in the sequence shown.
Torque:
No. 1 23 N´m (235 kgf´cm, 17 ft´lbf)
No. 2 12.7 N´m (130 kgf´cm, 10 ft´lbf)
4. INSTALL VALVE TIMING CONTROLLER ASSEMBLY
AND CAMSHAFT TIMING SPROCKET
(a) Apply engine oil in the rage from the tip of the intake cam-
shaft to 16 mm from that tip.
(b) Except leaded gasoline spec:
Align the timing mark on the valve timing controller as-
sembly with the knock pin, and install the value timing
controller assembly to the camshaft.
NOTICE:
Do not push valve timing controller assembly to the cam-
shaft forcibly when installing it.
(c) Align the knock pin hole in the camshaft timing sprocket
with the knock pin of the camshaft, and install the sprock-
et to the camshaft.

EM1J0±02
A13907
A13943
± ENGINE MECHANICALENGINE UNIT
EM±53
2001 PRIUS (RM778U)
REMOVAL
1. DISCONNECT BATTERY NEGATIVE (±) TERMINAL
AND HV BATTERY SERVICE PLUG
(See page HV±1)
2. REMOVE OUTER FRONT COWL TOP PANEL AS-
SEMBLY (See page BO±32)
3. DRAIN HV COOLANT (See page HT±8)
4. DRAIN ENGINE COOLANT
5. REMOVE CONVERTER AND INVERTER ASSEMBLY
(See page HV±18)
6. REMOVE HEATER UNIT WATER PUMP
(See page AC±55)
7. REMOVE AIR CLEANER ASSEMBLY
(a) Disconnect the MAF meter connector.
(b) Disconnect the EVAP hose from the air cleaner case.
(c) Loosen the 2 hose clamps.
(d) Remove the 2 bolts and air cleaner assembly.
8. DISCONNECT CONNECTORS, CLAMPS AND HOSES
(a) Disconnect the engine wire clamps.
(b) Disconnect the heated oxygen sensor connector.
(c) Disconnect the 2 power steering connectors.
(d) Disconnect the VSV connector for purge line.
(e) Disconnect the VSV hose for purge line.
(f) Disconnect the ground strap from RH fender apron.
(g) Disconnect the ground strap from LH fender apron.
9. REMOVE AIR INLET
10. REMOVE ENGINE COOLANT RESERVOIR TANK
11. DISCONNECT 2 RADIATOR HOSES FROM RADIATOR
12. DISCONNECT HEATER HOSE FROM CYLINDER
BLOCK

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

CO04E±09
B11768
Engine
Drain Plug
Radiator
Drain Plug
CO±2
± COOLINGCOOLANT
2001 PRIUS (RM778U)
REPLACEMENT
1. DRAIN ENGINE COOLANT
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
(b) Loosen the radiator drain plug (on the right side of the ra-
diator lower tank) and engine drain plug on the engine
coolant drain union (on the right front of the cylinder
block), and drain the coolant.
(c) Close the drain plugs.
Torque: 12.7 N´m (130 kgf´cm, 9 ft´lbf) for engine
2. FILL ENGINE COOLANT
(a) Slowly fill the system with coolant.

Use of improper coolants may damage the engine
cooling system.

Use ºToyota Long Life Coolantº or equivalent and
mix it with plain water according to the manufacture
directions.

Use of the coolant which includes more than 50%
[freezing protection down to ±35°C (±31°F)] or 60%
[freezing protection down to ±50°C (±58°F)] of eth-
ylene±glycol is recommended, but not more than
70%.
NOTICE:

Do not use an alcohol type coolant or plain water
alone.

The coolant should be mixed with plain water (prefer-
ably demineralized water or distilled water).
Capacity: 4.9 litters (5.2 US qts, 4.3 lmp qts)
(b) Install the radiator cap and start the engine. After repeat-
edly idling and racing the engine several times for approx.
2 minutes, stop the engine.
(c) Remove the radiator cap and fill the radiator with engine
coolant until it reaches the rim of the radiator filler.
If the engine coolant level of the radiator drops when grasping
the radiator inlet hose and outlet hose several times by hand,
add more coolant.
(d) Install the radiator cap. Activate inspection mode (See
page IN±10). Warm it up until the radiator fan starts to turn
with the engine speed at less than 2,500 rpm.
NOTICE:
Stop the engine immediately after the radiator fan starts to
turn.
(e) Stop the engine and cool it down.
NOTICE:
Cool down the engine until its temperature becomes below
50°C (122 °F).

± COOLINGCOOLANT
CO±3
2001 PRIUS (RM778U)
(f) Remove the radiator cap and check the engine coolant
level of the radiator. If it has dropped, repeat steps (d) to
(g).
(g) Bleed air from water pump.
Set the vehicle in the following conditions:

Ignition switch ON

Blower speed control dial to LO

Temperature control dial to MAX. HOT
(h) Operate the water pump in the following conditions:

The engine stopped

The blower switch ON

Temperature control dial at MAX. HOT
HINT:
Operate the water pump until a sound of the air±containing en-
gine coolant can not be heard from the heater core.
(i) When the engine coolant remains full, fill the radiator res-
ervoir tank with engine coolant to the maximum level.
3. CHECK FOR COOLANT LEAKS
4. CHECK ENGINE COOLANT SPECIFIC GRAVITY IS
CORRECT

CO143±01
Z00570
Radiator Cap Tester
Radiator Cap
30° or More CO±14
± COOLINGRADIATOR AND CONDENSER MODULE
2001 PRIUS (RM778U)
ON±VEHICLE INSPECTION
1. REMOVE RADIATOR CAP
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
2. INSPECT RADIATOR CAP
NOTICE:

If the radiator cap has contaminations, always rinse
it with water.

Before using a radiator cap tester, wet the relief valve
and pressure valve with engine coolant or water.

When performing steps (a) and (b) below, keep the ra-
diator cap tester at an angle of over 30°above the hor-
izontal.
(a) Using a radiator cap tester, slowly pump the tester and
check that air is coming from the vacuum valve.
Pump speed: 1 push/(3 seconds or more)
NOTICE:
Push the pump at a constant speed.
If air is not coming from the vacuum valve, replace the radiator
cap.
(b) Pump the tester and measure the relief valve opening
pressure.
Pump speed: 1 push within 1 seconds
NOTICE:
This pump speed is for the first pump only (in order to close
the vacuum value). After this, the pump speed can be re-
duced.
Standard opening pressure:
74 ± 103 kPa (0.75 ± 1.05 kgf´cm
2, 10.7 ± 14.9 psi)
Minimum opening pressure:
79 kPa (0.8 kgf´cm
2, 11.5 psi)
HINT:
Use the tester's maximum reading as the opening pressure. If
the opening pressure is less than minimum, replace the radiator
cap.

B11773
Radiator Cap Tester
± COOLINGRADIATOR AND CONDENSER MODULE
CO±15
2001 PRIUS (RM778U)
3. INSPECT COOLING SYSTEM FOR LEAKS
(a) Fill the radiator with coolant and attach a radiator cap tes-
ter.
(b) Warm up the engine.
(c) Pump it to 118 kPa (1.2 kgf´cm
2, 17.1 psi), and check that
the pressure drops.
If the pressure drops, check the hoses, radiator or water pump
for leaks. If no external leaks are found, check the heater core,
cylinder block and head.
4. REINSTALL RADIATOR CAP