engine TOYOTA PRIUS 2001 Service Repair Manual

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)

EM1IU±03
A13907
A13908
A13934
A13943
± ENGINE MECHANICALTIMING CHAIN
EM±15
2001 PRIUS (RM778U)
REMOVAL
1. DISCONNECT BATTERY NEGATIVE (±) TERMINAL
AND HV BATTERY SERVICE PLUG
(See page HV±1)
2. REMOVE OUTER FR COWL TOP PANEL ASSEMBLY
(See page BO±32)
3. REMOVE RH ENGINE UNDER COVER
4. DRAIN ENGINE COOLANT
5. 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 3 bolts and air cleaner assembly.
6. REMOVE BRAKE RESERVOIR TANK
(a) Disconnect the brake fluid level sensor connector.
(b) Remove the 2 bolts and remove the reservoir tank and
suspend it.
(c) Remove the 3 bolts and reservoir tank bracket.
7. DISCONNECT CONNECTORS
(a) Disconnect the 4 ignition connectors.
(b) Disconnect the 4 injector connectors.
(c) Disconnect the 2 VSV connectors.
(d) Disconnect the camshaft position sensor connector.
(e) Disconnect the water temperature connector.
(f) Disconnect the Camshaft timing oil control valve connec-
tor.
8. REMOVE AIR INLET
9. REMOVE ENGINE COOLANT RESERVOIR TANK
10. REMOVE VSV FROM ENGINE MOUNTING INSULA-
TOR
11. REMOVE DRIVE BELT

A13927
A13928
B11761
A11222
A11244
EM±16
± ENGINE MECHANICALTIMING CHAIN
2001 PRIUS (RM778U)
12. REMOVE RH ENGINE MOUNTING INSULATOR
(a) Set the jack to the engine.
HINT:
Place the wooden block between the jack and engine.
(b) Remove the 5 bolts, 2 nuts and RH engine mounting insu-
lator.
13. DISCONNECT ENGINE WIRE FROM CYLINDER HEAD
COVER
Remove the 3 bolts and disconnect the engine wire from the cyl-
inder head.
14. REMOVE CYLINDER HEAD COVER
(a) Remove the ignition coils (See page IG±6)
(b) Remove the 2 PCV hoses from the cylinder head cover.
(c) Remove the 7 bolts, 2 seal washers, 2 nuts, cylinder head
cover and gasket.
15. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with timing
mark º0º of the timing chain cover.

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.

EM±18
± ENGINE MECHANICALTIMING CHAIN
2001 PRIUS (RM778U)
(d) Remove the 2 O±rings from the cylinder block and oil pan
No.1.
22. REMOVE CHAIN TENSIONER
Remove the 2 bolts and chain tensioner.
23. REMOVE CHAIN TENSIONER SLIPPER
24. REMOVE CHAIN VIBRATION DAMPER
Remove the 2 bolts and damper.
25. REMOVE TIMING CHAIN

EM1IV±02
A11224
ATDC20°Mark Link
Timing Mark
30°
Timing Mark
Mark Link
A11225
± ENGINE MECHANICALTIMING CHAIN
EM±21
2001 PRIUS (RM778U)
INSTALLATION
1. INSTALL TIMING CHAIN
(a) After setting the crankshaft at ATDC40±140 °, set cams
of intake and exhaust timing sprockets at ATDC 20 ° and
then the reset the crankshaft at ATDC 20 °.
(b) Install the chain vibration damper with the 2 bolts.
Torque: 9.0 N´m (92 kgf´cm, 80 in.´lbf)
(c) Align the match marks of timing chain mark plate (Yellow),
camshaft timing sprocket, camshaft timing gear and
crankshaft timing sprocket to install the timing chain as
shown in the illustration.
HINT:
To prevent the exhaust camshaft from spring back turn it using
a wrench and set it at the mark on a chain.
(d) Install the chain tensioner slipper.
2. INSTALL CHAIN TENSIONER
(a) While rotating the lock plate of the tensioner up±ward,
push in the plunger of the tensioner as shown in the il-
lustration.
(b) While rotating the lock plate of the tensioner down±ward,
insert a bar of 2.5 mm (0.098 in.) into the holes in the lock
plate.
(c) Install the chain tensioner with the 2 bolts.
Torque: 9.0 N´m (92 kgf´cm, 80 in.´lbf)
(d) Remove the bar from the chain tensioner.
(e) Check that the tension between the intake and exhaust
camshaft timing sprocket.

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)

A11262
SST
SST
B00301
Seal
Packing
A11222
1
23
4
5
6
7
8
9
10
11
B11761
A13928
EM±24
± ENGINE MECHANICALTIMING CHAIN
2001 PRIUS (RM778U)
7. INSTALL CRANKSHAFT PULLEY
(a) Clean the crankshaft pulley inside.
(b) Install the pin to the crankshaft.
(c) Align the hole in the crank pulley with the pin position and
install the crank pulley.
(d) Using SST, install the pulley bolt.
SST 09213±70010, 09330±00021
Torque: 128 N´m (1,300 kgf´cm, 94 ft´lbf)
8. INSTALL CYLINDER HEAD COVER
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to 2 locations as shown in the illustra-
tion.
Seal packing:
Part No. 08826 ± 00080 or equivalent
(c) Install the gasket to the cylinder head cover.
HINT:
Part must be assembled within 3 minutes of application.
Otherwise the material must be remove and reapplied.
(d) Install the cylinder head cover and cable bracket with the
7 bolts, 2 seal washers and 2 nuts.
Uniformly tighten the bolts and nuts, in the several
passes, in the sequence shown.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
(e) Connect the 2 PCV hoses to the cylinder head cover.
9. CONNECT ENGINE WIRE TO CYLINDER HEAD COV-
ER
10. INSTALL IGNITION COILS (See page IG±7)
11. REMOVE RH ENGINE MOUNTING INSULATOR
Install the RH engine mounting insulator with the 5 bolts and 2
nuts.
12. INSTALL VSV TO RH ENGINE MOUNTING INSULA-
TOR
13. INSTALL DRIVE BELT
14. INSTALL ENGINE COOLANT RESERVOIR TANK
15. INSTALL AIR INLET

A13934
A13907
± ENGINE MECHANICALTIMING CHAIN
EM±25
2001 PRIUS (RM778U)
16. CONNECT CONNECTORS
(a) Connect the Camshaft timing oil control valve connector.
(b) Connect the water temperature sensor connector.
(c) Connect the camshaft position sensor connector.
(d) Connect the 2 VSV connectors.
(e) Connect the 4 injector connectors.
(f) Connect the 4 ignition connectors.
17. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner assembly with the 2 bolts.
(b) Tighten the 2 hose clamps.
(c) Connect the EVAP hose to the air cleaner case.
(d) Connect the MAF meter connector.
18. INSTALL BRAKE RESERVOIR TANK
19. INSTALL OUTER FR COWL TOP PANEL ASSEMBLY
(See page BO±35)
20. FILL WITH ENGINE COOLANT
21. INSTALL ENGINE UNDER COVERS
22. CONNECT BATTERY NEGATIVE (±) TERMINAL AND
HV BATTERY SERVICE PLUG (See page HV±1)
23. ROAD TEST VEHICLE
Check for abnormal noises, shock slippage, correst shift points
and smooth operation.
24. RECHECK ENGINE COOLANT AND HV TRANSAXLE
COOLANT