engine TOYOTA PRIUS 2001 Service Repair Manual

EM1IW±02
A13929
N´m (kgf´cm, ft´lbf)
Gasket
: Specified torque VSV for EVAPR/B (ABS) Air Cleaner
Assembly
RH Engine Mounting
Insulator Engine Coolant
Reservoir Tank
Engine Under
Cover RHOuter Front Cowl
Top Panel Air Inlet
60 (612, 44)
52 (530, 38)
52 (530, 38)
26 (265, 19)Brake Reservoir
Tank
Wiper Motor and
Wiper Link
Assembly
Cowl Top Ventilator
Lower LH
Cowl Top Ventilator
Lower RH
Wiper Arm
7 (71, 62 in. lbf)
26 (265, 19)
Hood to Cowl Top
Seal
62 (630, 46)
Front Exhaust Pipe
EM±26
± ENGINE MECHANICALCYLINDER HEAD
1142 Author: Date:
2001 PRIUS (RM778U)
CYLINDER HEAD
COMPONENTS

A13930
N´m (kgf´cm, ft´lbf)

Non±reusable part: Specified torque Heat Insulator
Exhaust Manifold
Ignition Coil
(w/ Igniter)
PCV Valve
Water Temprature
Sensor
Camshaft Position
Sensor
Engine Wire
Oil Dipstick
and Oil GuideThrottle Body
Assembly O±Ring

Gasket


Engine Wire
Gasket

27 (275, 20)
Oil Filter
20 (204, 15)
PCV Hose
Oil Control
Valve
20 (204, 15)
Intake Manifold
Spark Plug
± ENGINE MECHANICALCYLINDER HEAD
EM±27
1143 Author: Date:
2001 PRIUS (RM778U)

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)

EM1IX±02
A13907
B11761
A13934
± ENGINE MECHANICALCYLINDER HEAD
EM±29
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 TRANSAXLE COOLANT
(See page HT±6)
4. DRAIN ENGINE COOLANT
5. REMOVE CONVERTER AND INVERTER ASSEMBLY
(See page HV±18)
6. 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.
7. REMOVE IGNITION COILS (See page IG±6)
8. REMOVE SPARK PLUGS (See page IG±1)
9. REMOVE PCV HOSES
10. REMOVE THROTTLE BODY (See page SF±28)
11. DISCONNECT ENGINE WIRE FROM CYLINDER HEAD
(a) Disconnect the ECT sensor connector.
(b) Disconnect the camshaft position sensor connector.
(c) Disconnect the oil control valve connector.
(d) Disconnect the 4 injector connectors.
(e) Remove the 3 bolts and disconnect the engine wire pro-
tector from the cylinder head cover.

A13935
A13932
A11226
A13933
EM±30
± ENGINE MECHANICALCYLINDER HEAD
2001 PRIUS (RM778U)
12. REMOVE INTAKE MANIFOLD
Remove the 3 bolts, 2 nuts intake manifold and gasket.
13. DISCONNECT FRONT EXHAUST PIPE FROM EX-
HAUST MANIFOLD
(a) Remove the 2 bolts and 2 springs holding the front ex-
haust pipe to the exhaust manifold.
(b) Remove the gasket.
14. REMOVE EXHAUST MANIFOLD STAY
Remove the 3 bolts and exhaust manifold stay.
15. REMOVE EXHAUST MANIFOLD
(a) Remove the 4 bolts and upper heat insulator.
(b) Remove the 3 bolts 2 nuts, exhaust manifold and gasket.
16. REMOVE CAMSHAFT POSITION SENSOR
17. REMOVE ECT SENSOR
18. REMOVE OIL CONTROL VALVE
19. REMOVE PCV VALVE
20. REMOVE OIL FILLER CAP
21. REMOVE HEAD COVER (See page EM±15)
22. REMOVE INJECTOR (See page SF±11)
23. REMOVE TIMING CHAIN COVER (See page EM±15)
24. REMOVE CAMSHAFT TIMING SPROCKET AND
VALVE TIMING CONTROL ASSEMBLY
Hold the hexagonal head portion of the camshaft with a wrench,
and remove the 2 bolts and timing sprocket and valve timing
controller assembly.
NOTICE:

Be careful not to damage the cylinder head and valve
lifter with the wrench.

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.

A01076
EM16K±03
A01077
A01068
A01069
A01070
± ENGINE MECHANICALCYLINDER HEAD
EM±33
2001 PRIUS (RM778U)
INSPECTION
1. CLEAN TOP SURFACES OF PISTONS AND CYL-
INDER BLOCK
(a) Turn the crankshaft, and bring each piston to top dead
center (TDC). Using a gasket scraper, remove all the car-
bon from the piston surface.
(b) Using a gasket scraper, remove all the gasket material
from the cylinder block surface.
(c) Using compressed air, blow carbon and oil from the bolt
holes.
CAUTION:
Protect your eyes when using high pressure compressed
air.
2. REMOVE GASKET MATERIAL
Using a gasket scraper, remove all the gasket material from the
cylinder block contact surface.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
3. CLEAN COMBUSTION CHAMBERS
Using a wire brush, remove all the carbon from the combustion
chambers.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
4. CLEAN CYLINDER HEAD
Using a soft brush and solvent, thoroughly clean the cylinder
head.

A01479
A01075
Cylinder Block Side
Intake Manifold Side
Exhaust Manifold Side
A01071
EM0580
EM±34
± ENGINE MECHANICALCYLINDER HEAD
2001 PRIUS (RM778U)
5. CLEAN VALVE GUIDE BUSHINGS
Using a valve guide bushing brush and solvent, clean all the
guide bushings.
6. INSPECT FOR FLATNESS
Using a precision straight edge and feeler gauge, measure the
surface contacting the cylinder block and the manifolds for war-
page.
Maximum warpage:
Cylinder block side0.05 mm (0.0020 in.)
Intake Manifold side0.10 mm (0.0394 in.)
Exhaust manifold side0.10 mm (0.0394 in.)
If warpage is greater than maximum, replace the cylinder head.
7. INSPECT FOR CRACKS
Using a dye penetrant, check the combustion chamber, intake
ports, exhaust ports and cylinder block surface for cracks.
If cracked, replace the cylinder head.
8. CLEAN VALVES
(a) Using a gasket scraper, chip off any carbon from the valve
head.
(b) Using a wire brush, thoroughly clean the valve.

A01478
Z00052
EM0180
44.5°
EM0181
Margin Thickness
± ENGINE MECHANICALCYLINDER HEAD
EM±35
2001 PRIUS (RM778U)
9. INSPECT VALVE STEMS AND GUIDE BUSHINGS
(a) Using a caliper gauge, measure the inside diameter of the
guide bushing.
Bushing inside diameter:
5.010 ± 5.030 mm (0.19724 ± 0.19803 in.)
(b) Using a micrometer, measure the diameter of the valve
stem.
Valve stem diameter:
Intake 4.970 ± 4.985 mm (0.19567 ± 0.19626 in.)
Exhaust 4.965 ± 4.980 mm (0.19547 ± 0.19606 in.)
(c) Subtract the valve stem diameter measurement from the
guide bushing inside diameter measurement.
Standard oil clearance:
Intake 0.025 ± 0.060 mm (0.00098 ± 0.00236 in.)
Exhaust 0.030 ± 0.065 mm (0.00118 ± 0.00256 in.)
Maximum oil clearance:
Intake 0.08 mm (0.0031 in.)
Exhaust 0.10 mm (0.0039 in.)
If the clearance is greater than maximum, replace the valve and
guide bushing.
10. INSPECT VALVES
(a) Check the valve is ground to the correct valve face angle.
Valve face angle: 44.5°
(b) Check that the surface of the valve for wear.
If the valve face is worn, replace the valve.
(c) Check the valve head margin thickness.
Standard margin thickness:
1.00 ± 1.15 mm (0.0393 ± 0.0453 in.)
Minimum margin thickness: 0.7 mm (0.028 in.)
If the margin thickness is less than minimum, replace the valve.

EM2534
Overall Length
A01073
45° Carbide
CutterResiduary
Width
Resurface
A01074
Width
EM0185
45°20°
1.0 ± 1.4 mm
EM0186
75°
1.0 ± 1.4 mm45°
EM±36
± ENGINE MECHANICALCYLINDER HEAD
2001 PRIUS (RM778U)
(d) Check the valve overall length.
Standard overall length:
Intake 89.25 mm (3.5138 in.)
Exhaust 87.90 mm (3.4606 in.)
Minimum overall length:
Intake 88.95 mm (3.5020 in.)
Exhaust 87.60 mm (3.4488 in.)
If the overall length is less than minimum, replace the valve.
(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
11. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45° carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
(b) Check the valve seating position.
Apply a light coat of prussian blue (or white lead) to the
valve face. Lightly press the valve against the seat. Do not
rotate valve.
(c) Check the valve face and seat for the following:

If blue appears 360° around the face, the valve is
concentric. If not, replace the valve.

If blue appears 360° around the valve seat, the
guide and face are concentric. If not, resurface the
seat.

Check that the seat contact is in the middle of the
valve face with the following width:
1.0 ± 1.4 mm (0.039 ± 0.055 in.)
If not, correct the valve seats as follows:
(1) If the seating is too high on the valve face, use 20°
and 45° cutters to correct the seat.
(2) If the seating is too low on the valve face, use 75°
and 45° cutters to correct the seat.