engine TOYOTA PRIUS 2001 Service Repair Manual

A10461
A10462
A10463
No. 1No. 2
No. 3
No. 4No. 5
No. 5
No. 4
No. 3
No. 2
No. 1
Number
Mark
Total number º º: Number mark
Cylinder block (A)
+
Crankshaft (B)
Use bearing0 ± 2 3 ± 5 6 ± 8 9 ±11
º1º
EXAMPLE: Cylinder block º4º (A)
+ Crankshaft º3º (B)
= Total number 7 (Use bearing º3º)º2º º3º º4º EM±68
± ENGINE MECHANICALCYLINDER BLOCK
2001 PRIUS (RM778U)
(e) Check each main journal and bearing for pitting and
scratches.
If the journal or bearing is damaged, replace the bearing.
If necessary, grind or replace the crankshaft.
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of plastigage acrose each journal.
(h) Install the bearing caps (See page EM±45).
Torque:
1ST 22 N´m (220 kgf´cm, 16 ft´lbf)
2ND Turn 90 °
NOTICE:
Do not turn the crankshaft.
(i) Remove the bearing caps (See procedure (a) and (b)
above).
(j) Measure the plastigage at its widest point.
Standard oil clearance:
0.010 ± 0.023 mm (0.0004 ± 0.0009 in.)
Maximum oil clearance:
0.07 mm (0.0028 in.)
If the oil clearance is greater then maximum, replace the bear-
ings. If necessary, replace the crankshaft.
HINT:
If using a standard bearing, replace it with one having the same
number. If the number of the bearing cannot be determined, se-
lect the correct bearing by adding together the numbers im-
printed on the cylinder block and crankshaft, then selecting the
bearing with the same number as the total. There are 4 sizes
of standard bearings, marked º1º, º2º, º3º and º4º accordingly.

A12947
A12948
± ENGINE MECHANICALCYLINDER BLOCK
EM±69
2001 PRIUS (RM778U)
Reference
ItemMarkmm (in.)
Cylinder block main journal bore diameter (A)º0º
º1º
º2º
º3º
º4º
º5º
º6º50.000 ± 50.003 (1.96850 ± 1.96862)
50.003 ± 50.005 (1.96862 ± 1.96870)
50.005 ± 50.007 (1.96870 ± 1.96878)
50.007 ± 50.010 (1.96878 ± 1.96889)
50.010 ± 50.012 (1.96889 ± 1.96897)
50.012 ± 50.014 (1.96897 ± 1.96905)
50.014 ± 50.016 (1.96905 ± 1.96913)
Crankshaft main journal diameter (B)º0º
º1º
º2º
º3º
º4º
º5º46.000 ± 46.002 (1.81102 ± 1.81110)
46.002 ± 46.004 (1.81110 ± 1.81118)
46.004 ± 46.006 (1.81118 ± 1.81126)
46.006 ± 46.008 (1.81126 ± 1.81133)
46.008 ± 46.010 (1.81133 ± 1.81141)
46.010 ± 46.012 (1.81141 ± 1.81149)
Standard bearing center wall thicknessº1º
º2º
º3º
º4º1.992 ± 1.995 (0.07843 ± 0.07854)
1.995 ± 1.998 (0.07854 ± 0.07866)
1.998 ± 2.001 (0.07866 ± 0.07878)
2.001 ± 2.004 (0.07878 ± 0.07890)
(k) Completely remove the Plastigage.
20. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the 5 upper main bearings and 2 thrust washers
from the cylinder block.
HINT:
Arrange the main bearings and thrust washers in the correct or-
der.
21. CHECK FIT BETWEEN PISTON AND PISTON PIN
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
22. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the oil ring by hand.
HINT:
Arrange the piston rings in the correct order only.

A12963
SSTSST
SST
EM±70
± ENGINE MECHANICALCYLINDER BLOCK
2001 PRIUS (RM778U)
23. DISCONNECT CONNECTING ROD FROM PISTON
Using SST, press out the piston pin from the piston. Remove the
piston.
SST 09221±25026 (09221±00021, 09221±00030,
09221±00190, 09221±00141, 09221±00150)
HINT:

The piston and pin are a matched set.

Arrange the pistons, pins, rings, connecting rods and
bearings in correct order.

EM17D±03
A01165
A01169
A01167
± ENGINE MECHANICALCYLINDER BLOCK
EM±71
2001 PRIUS (RM778U)
INSPECTION
1. REMOVE GASKET MATERIAL
Using a gasket scraper, remove all the gasket material from the
top surface of the cylinder block.
2. CLEAN CYLINDER BLOCK
Using a soft brush and solvent, thoroughly clean the cylinder
block.
NOTICE:
If the cylinder is washed at high temperatures, the cylinder
liner sticks out beyond the cylinder block, so always wash
the cylinder block at a temperature of 45°C (133°F) or less.
3. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR
FLATNESS
Using a precision straight edge and feeler gauge, measure the
surface contacting the cylinder head gasket for warpage.
Maximum warpage: 0.05 mm (0.0020 in.)
If warpage is greater than maximum, replace the cylinder block.
4. INSPECT CYLINDER BORE DIAMETER
Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block.

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.

A12950
A12951
A1295227 mm
A12953
± ENGINE MECHANICALCYLINDER BLOCK
EM±73
2001 PRIUS (RM778U)
(b) Using a groove cleaning tool or broken ring, clean the pis-
ton ring grooves.
(c) Using solvent and a brush, thoroughly clean the piston.
NOTICE:
Do not use a wire brush.
9. INSPECT PISTON OIL CLEARANCE
(a) Using a micrometer, while placing the piston up side
down, take measurement at the position of 27 mm (1.06
in.).
Piston diameter:
74.930 ± 74.940 mm (2.94999 ± 2.95039 in.)
(b) Measure the cylinder bore diameter in the thrust direc-
tions. (See procedure in step 5)
(c) Subtract the piston diameter measurement from the cylin-
der bore diameter measurement.
Standard oil clearance:
0.045 ± 0.068 mm (0.00177 ± 0.00268 in.)
Maximum oil clearance:
0.095 mm (0.0037 in.)
If the oil clearance is greater than maximum, replace all the 4
pistons. If necessary, replace the cylinder block.
10. INSPECT PISTON RING END GAP
Using a feeler gauge, measure the clearance between new pis-
ton ring and the wall of the ring groove.
Ring groove clearance:
0.030 ± 0.070 mm (0.0012 ± 0.0028 in.)
If the clearance is not as specified, replace the piston.

A12954
11 0
mm
EM7639
Z00064
Z00065
A01185
EM±74
± ENGINE MECHANICALCYLINDER BLOCK
2001 PRIUS (RM778U)
11. INSPECT PISTON RING END GAP
(a) Insert the piston ring into the cylinder bore.
(b) Using a piston, push the piston ring a little beyond the bot-
tom of the ring travel, 110 mm (4.33 in.) from the top of the
cylinder block.
(c) Using a feeler gauge, measure the end gap.
Standard end gap:
No. 1 0.22 ± 0.32 mm (0.0087 ± 0.0126 in.)
No. 2 0.32 ± 0.47 mm (0.0126 ± 0.0185 in.)
Oil (Side rail) 0.15 ± 0.45 mm (0.0059 ± 0.0177 in.)
Maximum end gap:
No. 1 0.88 mm (0.0346 in.)
No. 2 1.03 mm (0.0406 in.)
Oil 0.92 mm (0.0362 in.)
If the end gap is greater than maximum, replace the piston ring.
If the end gap is greater than maximum, even with a new piston
ring, replace the cylinder block.
12. INSPECT CONNECTING ROD ALIGNMENT
Using a rod aligner and feeler gauge, check the connecting rod
alignment.

Check for out±of±alignment
Maximum out±of alignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If out±of alignment is greater than maximum, replace the con-
necting rod assembly.

Check for twist
Maximum twist:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod as-
sembly.
13. INSPECT PISTON PIN OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the
connecting rod bushing.
Bushing inside diameter:
18.010 ± 18.019 mm (0.7091 ± 0.7094 in.)

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.

A11242
EM±76
± ENGINE MECHANICALCYLINDER BLOCK
2001 PRIUS (RM778U)
16. INSPECT MAIN JOURNALS AND CRANK PINS
(a) Using a micrometer, measure the diameter of each main
journal and crank pin.
Main journal diameter:
45.988 ± 46.000 mm (1.81054 ± 1.81102 in.)
Crank pin diameter:
39.992 ± 40.000 mm (1.5745 ± 1.5748 in.)
If the diameter is not as specified, check the oil clearance.
(See page EM±64)
If necessary, replace the crankshaft.
(b) Check each main journal and crank pin for taper and out±
of±round as shown.
Maximum taper and out±of±round:
0.02 mm (0.0008 in.)
If the taper and out±of round is greater than maximum, replace
the crankshaft.

EM1J4±02
A12957
(Cavity)
(Protrusion)Front Mark
SST
SST SST
A12958
No. 2
A12959
Oil Ring
(Expander)
No. 2 CompressionOil Ring (Rail)
No. 1 Compression
Front EM±78
± ENGINE MECHANICALCYLINDER BLOCK
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 all gaskets, O±rings and oil seals with new parts.
1. ASSEMBLE PISTON AND CONNECTING ROD
(a) Gradually heat the piston side of connecting rod to 80 ±
90°C (176 ± 194°F).
(b) Coat the piston pin and pin holes of the piston with engine
oil.
(c) Align the cavity on the piston with the protrusion on the
connecting rod.
(d) Using SST, press in the piston pin.
SST 09221±25026 (09221±00021, 09221±00030,
09221±00190, 09221±00141, 09221±00150)
2. INSTALL PISTON RINGS
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings.
(c) Position the piston rings so that the ring ends are as
shown.
NOTICE:
Do not align the ring ends.