TOYOTA PRIUS 2001 Service Repair Manual

SS174±03
SS±6
± SERVICE SPECIFICATIONSENGINE MECHANICAL
128 Author: Date:
2001 PRIUS (RM778U)
ENGINE MECHANICAL
SERVICE DATA
Compression
pressureat 250 rpm STD
Minimum
Difference between each cylinder728 kPa (7.4 kgf/cm2, 106 psi)
534 kPa (5.4 kgf/cm2, 77 psi)
98 kPa (1.0 kgf/cm2, 14 psi)
Valve
clearance
at cold Intake
Exhaust
Valve lifter for repair part No. 06
No. 08
No. 10
No. 12
No. 14
No. 16
No. 18
No. 20
No. 22
No. 24
No. 26
No. 28
No. 30
No. 32
No. 34
No. 36
No. 38
No. 40
No. 42
No. 44
No. 46
No. 48
No. 50
No. 52
No. 54
No, 56
No. 58
No. 60
No. 62
No. 64
No. 66
No. 68
No. 70
No. 72
No. 740.17 ± 0.23 mm (0.007 ± 0.009 in.)
0.27 ± 0.33 mm (0.011 ± 0.013 in.)
5.060 mm (0.1992 in.)
5.080 mm (0.2000 in.)
5.100 mm (0.2008 in.)
5.120 mm (0.2016 in.)
5.140 mm (0.2024 in.)
5.160 mm (0.2031 in.)
5.180 mm (0.2039 in.)
5.200 mm (0.2047 in.)
5.220 mm (0.2055 in.)
5.240 mm (0.2063 in.)
5.260 mm (0.2071 in.)
5.280 mm (0.2079 in.)
5.300 mm (0.2087 in.)
5.320 mm (0.2094 in.)
5.340 mm (0.2102 in.)
5.360 mm (0.2110 in.)
5.380 mm (0.2118 in.)
5.400 mm (0.2126 in.)
5.420 mm (0.2134 in.)
5.440 mm (0.2142 in.)
5.460 mm (0.2150 in.)
5.480 mm (0.2157 in.)
5.500 mm (0.2165 in.)
5.520 mm (0.2173 in.)
5.540 mm (0.2181 in.)
5.560 mm (0.2189 in.)
5.580 mm (0.2197 in.)
5.600 mm (0.2205 in.)
5.620 mm (0.2213 in.)
5.640 mm (0.2220 in.)
5.660 mm (0.2228 in.)
5.680 mm (0.2236 in.)
5.700 mm (0.2244 in.)
5.720 mm (0.2252 in.)
5.740 mm (0.2260 in.)
Ignition timing7 ± 15° BTDC @ idle
Idle speedw/ Cooling fan off1,000 ± 50 rpm (A/C OFF)
1,200 ± 50 rpm (A/C ON)
Chain and
timing sprocketChain length at 16 linksMaximum
Camshaft timing sprocket wear (w/ chain) Minimum
Crankshaft timing sprocket wear (w/ chain) Minimum123.2 mm (4.850 in.)
96.2 mm (3.787 in.)
50.5 mm (1.988 in.)
Chain
tensioner
slipper and
vibration
damperWear Maximum1.0 mm (0.039 in.)

± SERVICE SPECIFICATIONSENGINE MECHANICAL
SS±7
129 Author: Date:
2001 PRIUS (RM778U) Cylinder head
Warpage
Cylinder brock side Maximum
Intake manifold sideMaximum
Exhaust manifold side Maximum
Valve seat
Refacing angle
Contacting angle
Contacting width
Valve guide bushing bore diameter STD
O/S 0.05
0.05 mm (0.0020 in.)
0.01 mm (0.0394 in.)
0.01 mm (0.0394 in.)
20°, 45°, 75°
45°
1.0 ± 1.4 mm (0.039 ± 0.055 in.)
9.685 ± 9.706 mm (0.38130 ± 0.38213 in.)
9.735 ± 9.756 mm (0.38327 ± 0.38493 in.)
Valve guide
bushingInside diameter
Protrusion height5.010 ± 5.030 mm (0.19724 ± 0.19803 in.)
9.0 ± 9.4 mm (0.354 ± 0.370 in.)
Valve
Valve overall length STD Intake
Exhaust
Minimum Intake
Exhaust
Valve face angle
Stem diameterIntake
Exhaust
Stem oil clearance STD Intake
Exhaust
Maximum Intake
Exhaust
Margin thickness STD
Minimum89.25 mm (3.5138 in.)
87.90 mm (3.4606 in.)
88.95 mm (3.5020 in.)
87.60 mm (3.4488 in.)
44.5°
4.970 ± 4.985 mm (0.19567 ± 0.19626 in.)
4.965 ± 4.980 mm (0.19547 ± 0.19606 in.)
0.025 ± 0.060 mm (0.00098 ± 0.00236 in.)
0.030 ± 0.065 mm (0.00118 ± 0.00256 in.)
0.08 mm (0.0031 in.)
0.10 mm (0.0039 in.)
1.00 ± 1.15 mm (0.039 ± 0.045 in.)
0.7 mm (0.028 in.)
Valve spring
Deviation Maximum
Angle (Reference) Maximum
Free length
Installed tension at 32.5 mm (1.280 in.)
Maximum working tension at 23.9 mm (0.941 in.)1.6 mm (0.063 in.)
2°
59.77 mm (2.353 in.)
140 ± 154 N (14.3 ± 15.7 kgf, 31.5 ± 34.6 lbf)
180 ± 198 N (18.4 ± 20.2 kgf, 40.4 ± 44.8 lbf)
Valve lifter
Lifter diameter
Lifter bore diameter
Oil clearance STD
Maximum30.966 ± 30.976 mm (1.21913 ± 1.21952 in.)
31.009 ± 31.025 mm (1.22082 ± 1.22145 in.)
0.031 ± 0.059 mm(0.00122 ± 0.00232 in.)
0.1 mm (0.004 in.)
Camshaft
Thrust clearance STD
Maximum
Journal oil clearance STD
Maximum
Journal diameter No. 1
Others
Circle run out Maximum
Cam lobe height
STD Intake
Exhaust
Minimum Intake
Exhaust0.040 ± 0.095 mm (0.0016 ± 0.0037 in.)
0.11 mm (0.0043 in.)
0.040 ± 0.095 mm (0.00157 ± 0.00374 in.)
0.115 mm (0.00453 in.)
34.449 ± 34.465 (1.35626 ± 1.35689 in.)
22.949 ± 22.965 (0.90350 ± 0.90413 in.)
0.03 mm (0.0012 in.)
42.310 ± 42.410 mm (1.62637 ± 1.66968 in.)
44.046 ± 44.146 mm (1.73409 ± 1.73803 in.)
42.16 mm (1.6598 in.)
43.90 mm (1.7283 in.)
Intake
manifoldWarpage Maximum0.10 mm (0.0039 in.)
Exhaust
manifoldWarpage Maximum0.70 mm (0.0276 in.)

SS±8
± SERVICE SPECIFICATIONSENGINE MECHANICAL
130 Author: Date:
2001 PRIUS (RM778U) Cylinder
block
Cylinder head surface warpage Maximum
Cylinder bore diameter STD
Maximum
Main journal bore diameter Mark 0
Mark 1
mark 2
Mark 3
Mark 4
Mark 5
Mark 6
12 pointed head bearing cap sub±assembly bolt diameter
at tension portion STD
Minimum0.05 mm (0.0020 in.)
75.000 ± 75.013 mm (2.95275 ± 2.95326 in.)
75.013 mm (2.95326 in.)
50.000 ± 50.003 mm (1.96850 ± 1.96862 in.)
50.003 ± 50.005 mm (1.96862 ± 1.96870 in.)
50.005 ± 50.007 mm (1.96870 ± 1.96878 in.)
50.007 ± 50.010 mm (1.96878 ± 1.96889 in.)
50.010 ± 50.012 mm (1.96889 ± 1.96897 in.)
50.012 ± 50.014 mm (1.96897 ± 1.96905 in.)
50.014 ± 50.016 mm (1.96905 ± 1.96913 in.)
7.3 ± 7.5 mm (0.287 ± 0.295 in.)
7.3 mm (0.287 in.)
Piston and
Piston ring
Piston diameter
at 27 mm (1.063 in.) from the piston head
Piston oil clearance STD
Maximum
Piston ring groove clearance
Piston ring end gap
STD No. 1
No. 2
Oil
Maximum No. 1
No. 2
Oil
74.945 ± 74.955 mm (2.95058 ± 2.95098 in.)
0.045 ± 0.068 mm (0.00177 ± 0.00268 in.)
0.08 mm (0.0031 in.)
0.030 ± 0.070 mm (0.0012 ± 0.0028 in.)
0.22 ± 0.32 mm (0.0087 ± 0.0126 in.)
0.32 ± 0.47 mm (0.0126 ± 0.0185 in.)
0.15 ± 0.45 mm (0.0059 ± 0.0177 in.)
0.88 mm (0.0346 in.)
1.03 mm (0.0406 in.)
0.92 mm (0.0362 in.)
Connecting
rod
Thrust clearance STD
Maximum
Connecting rod thickness
Connecting rod bearing center wall thickness
Reference Mark 1
Mark 2
Mark 3
Connecting rod oil clearance STD
Maximum
Rod out±of±alignment Maximum per 100 mm (3.94 in.)
Rod twist Maximum per 100 mm (3.94 in.)
Bushing inside diameter
Piston pin diameter
Bushing oil clearance STD
Maximum
Connecting rod bolt diameter
at tension portion STD
Minimum0.16 ± 0.36 mm (0.0063 ± 0.0142 in.)
0.36 mm (0.0142 in.)
19.788 ± 19.840 mm (0.779 ± 0.781 in.)
1.488 ± 1.492 mm (0.0586 ± 0.0587 in.)
1.492 ± 1.496 mm (0.0587 ± 0.0589 in.)
1.496 ± 1.500 mm (0.0589 ± 0.0591 in.)
0.016 ± 0.040 mm (0.0006 ± 0.0016 in.)
0.06 mm (0.0024 in.)
0.05 mm (0.0020 in.)
0.05 mm (0.0020 in.)
18.010 ± 18.019 mm (0.7091 ± 0.7094 in.)
17.988 ± 18.007 mm (0.7086 ± 0.7089 in.)
0.009 ± 0.015 mm (0.0003 ± 0.0006 in.)
0.05 mm (0.0020 in.)
6.6 ± 6.7 mm (0.260 ± 0.264 in.)
6.4 mm (0.252 in.)

± SERVICE SPECIFICATIONSENGINE MECHANICAL
SS±9
131 Author: Date:
2001 PRIUS (RM778U) Crankshaft
Thrust clearance STD
Maximum
Thrust washer thickness
Main journal oil clearance STD
Maximum
Main journal diameter
Reference Mark 0
Mark 1
Mark 2
Mark 3
Mark 4
Mark 5
Main bearing center wall thickness
Reference Mark 1
Mark 2
Mark 3
Mark 4
Crank pin diameter
Circle run out Maximum
Main journal taper and out±of roundMaximum
Crank pin taper and out±of roundMaximum0.090 ± 0.190 mm (0.00354 ± 0.00748 in.)
0.30 mm (0.012 in.)
2.430 ± 2.480 mm (0.09567 ± 0.09764 in.)
0.010 ± 0.023 mm (0.0004 ± 0.0009 in.)
0.07 mm (0.0028 in.)
45.988 ± 45.990 mm (1.81054 ± 1.81062 in.)
45.990 ± 45.992 mm (1.81062 ± 1.81071 in.)
45.992 ± 45.994 mm (1.81071 ± 1.81078 in.)
45.994 ± 45.996 mm (1.81078 ± 1.81086 in.)
45.996 ± 45.998 mm (1.81086 ± 1.81094 in.)
45.998 ± 46.000 mm (1.81094 ± 1.81102 in.)
1.992 ± 1.995 mm (0.07843 ± 0.07854 in.)
1.995 ± 1.998 mm (0.07854 ± 0.07866 in.)
1.998 ± 2.001 mm (0.07866 ± 0.07878 in.)
2.001 ± 2.004 mm (0.07878 ± 0.07890 in.)
39.992 ± 40.000 mm (1.5745 ± 1.5748 in.)
0.03 mm (0.0012 in.)
0.02 mm (0.0008 in.)
0.02 mm (0.0008 in.)

SS175±03
SS±10
± SERVICE SPECIFICATIONSENGINE MECHANICAL
2001 PRIUS (RM778U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Plug x Timing chain cover1515011
Chain vibration damper x Cylinder block9.09280 in .´lbf
Chain tensioner9.09280 in .´lbf
Timing chain cover Bolt A
Bolt B
Bolt C
Bolt D
Bolt E
Nut F
Nut G11
24
11
24
11
24
1111 2
245
11 2
245
11 2
245
11 28
18
8
18
8
18
8
RH engine mounting bracket x Timing chain cover5556141
Crankshaft position sensor x Timing chain cover Bolt A
Bolt B7.5
1176
11 266 in .´lbf
8
Oil control valve8.08271 in .´lbf
Crankshaft pulley x Crankshaft1281,30094
Cylinder head cover x Cylinder101007
RH engine mounting insulator Bolt A
Bolt B
Nut45
52
52459
530
53033
38
38
Cylinder head x Cylinder block 1st
2nd
3rd29.4
Turn 90°
Turn 90°300
Turn 90°
Turn 90°22
Turn 90°
Turn 90°
Water bypass pipe x Cylinder head9.09280 in .´lbf
No. 1 camshaft bearing cap x Cylinder head2323517
No. 2 camshaft bearing cap x Cylinder head12.713010
Camshaft timing sprocket x Camshaft6465047
Valve timing controller assembly x Camshaft6465047
Intake manifold x Cylinder head2020415
Exhaust manifold x Cylinder head2727520
Upper heat insulator x Exhaust manifold8.08271 in .´lbf
Exhaust manifold stay x Cylinder block2727520
Front exhaust pipe x Tailpipe Bolt A
Bolt B62
32630
33046
24
Connecting rod cap x Connecting rod 1st
2nd15
Turn 90°150
Turn 90°11
Turn 90°
Bearing cap x Cylinder block 1st
2nd22
Turn 90°220
Turn 90°16
Turn 90°
Oil pan No. 1 x Cylinder block2424518
Oil strainer x Oil pan No. 11111 28
Oil pan No. 2 x Oil pan No. 19.09280 in.´lbf
Oil filter union x Oil pan No. 13030621
Engine coolant drain plug x Cylinder block12.71309
Knock sensor x Cylinder block4445033
Water bypass pipe x Cylinder block9.09080 in.´lbf
Flywheel x Crankshaft8485762
Damper spring x Flywheel1616312

SS17E±01
± SERVICE SPECIFICATIONSEMISSION CONTROL
SS±11
133 Author: Date:
2001 PRIUS (RM778U)
EMISSION CONTROL
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
PCV valve x Cylinder head cover2727520

SS102±07
SS±12
± SERVICE SPECIFICATIONSSFI
134 Author: Date:
2001 PRIUS (RM778U)
SFI
SERVICE DATA
Fuel pumpResistance at 20°C (68°F)0.2 ± 3.0 W
InjectorResistance at 21 °C (68 °F)
Injection volume
Difference between each cylinder
Fuel leakage13.4 ± 14.2 W
36 ± 46 cm3 (2.1 ± 2.8 cu in.) per 15 sec.
10 cm3 (0.7 cu in.) or less
1 drop or less per 12 minutes
Mass air flow me-
ter
Resistance
at ±20°C (±4°F) THA ± E2
at 20°C (68°F) THA ± E2
at 60°C (140°F) THA ± E2
13.6 ± 18.4 kW
2.21 ± 2.69 kW
0.49 ± 0.67 kW
Throttle control
motorResistance
at 20°C (68°F) M+ ± M±
0.3 ± 100 W
Throttle position
sensorResistance
at 20°C (68°F) VC ± E2
1.2 ± 3.2 kW
VSV for EVAPResistance at 20°C (68°F)27 ± 33 W
VSV for CCVResistance at 20°C (68°F)25 ± 30 W
VSV for Purge
flow switching
valve
Resistance at 20°C (68°F)33 ± 39 W
VSV for HCACResistance at 20°C (68°F)33 ± 39 W
ECT sensorResistance at ±20°C (±4°F)
at 0°C (32°F)
at 20°C (68°F)
at 40°C (104°F)
at 60°C (140°F)
at 80°C (176°F)10 ± 20 kW
4 ± 7 kW
2 ± 3 kW
0.9 ± 1.3 kW
0.4 ± 0.7 kW
0.2 ± 0.4 kW
Vacuum sensor
for HCACPower sorce voltage4.5 ± 5.5 V
Vapor pressure
sevsorPower sorce voltage
Output voltage4.5 ± 5.5 V
3.0 ± 3.6 V
Heated
oxygen sensorHeater coil resistance at 20°C (68°F)11 ± 16 W
Accelerator pedal
position sensorResistance
at 20°C (68°F) Vcp
1 ± Ep1
Vcp2 ± Ep21.5 ± 6.0 kW
Fuel cut rpmFuel return rpm1,400 rpm

SS103±06
± SERVICE SPECIFICATIONSSFI
SS±13
2001 PRIUS (RM778U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Fuel pump assembly x Fuel tank4.04035 in.´lbf
Delivery pipe x Cylinder head1919414
Throttle body x Intake manifold2020415
Camshaft timing oil control valve x Cylinder head7.57666 in.´lbf
Knock sensor x Cylinder block4445033
Heated oxygen sensor (Bank1 sensor1) x Exhaust manifold4444031
Heated oxygen sensor (Bank1 sensor2) x Exhaust pipe4444031

SS176±03
SS±14
± SERVICE SPECIFICATIONSCOOLING
136 Author: Date:
2001 PRIUS (RM778U)
COOLING
SERVICE DATA
Drive beltTension (Reference) New belt
Used belt110 ± 11 lbf
67 ± 10 lbf
ThermostatValve opening temperature
at 90°C (199°F)80.0 ± 84.0°C (176 ± 183°F)
8.5 mm (0.345 in.) or more
Radiator capRelief valve opening pressure STD
Minimum74 ± 103 kPa (0.75 ± 1.05 kgf/cm2, 10.7 ± 14.9 psi)
79 kPa (0.8kgf/cm2, 11.5 psi)
Electric
cooling fanAmperage STD9.2 ± 11.0 A

SS177±02
± SERVICE SPECIFICATIONSCOOLING
SS±15
2001 PRIUS (RM778U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Drain plug12.71309
Water pump x Timing chain cover1111 08
Pump pulley x Water pump1515011
Water inlet x Cylinder block9.09080 in.´lbf
Electric cooling fan assembly x Radiator7.57666 in.´lbf
Fan motor x Fan shroud2.652723 in.´lbf
Fan x Fan motor6.46657 in.´lbf