engine TOYOTA PRIUS 2001 Service Repair Manual

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

CO145±01
I17955
I17954
± COOLINGRADIATOR AND CONDENSER MODULE
CO±17
2001 PRIUS (RM778U)
REMOVAL
1. DISCHARGE REFRIGERANT FROM REFRIGERATION
SYSTEM
HINT:
At the time of installation, please refer to the following item.
Evacuate air from refrigeration system.
Charge system with refrigerant and inspect for leakage of refrig-
erant.
Specified amount: 500 ± 50 g (17.64 ± 1.76 oz.)
2. DRAIN ENGINE COOLANT FROM RADIATOR
HINT:
It is not necessary to drain out all the coolant.
3. REMOVE ELECTRIC COOLING FAN ASSEMBLY
(See Page CO±22)
4. REMOVE FRONT BUMPER (See Page BO±4)
5. REMOVE RADIATOR RESERVOIR HOSE
6. DISCONNECT DISCHARGE AND LIQUID TUBE
(a) Remove the 2 bolts and disconnect discharge and liquid
tube.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
NOTICE:
Cap open the fittings immediately to keep moisture or dirt
out of the system.
HINT:
At the time of installation, please refer to the following item.
Lubricate 2 new O±rings with compressor oil and install them
to the tubes.
(b) Remove the bolt.
(c) Disconnect the liquid tube and remove the bracket.
7. REMOVE RADIATOR UPPER SUPPORT
Remove the 2 bolts and 2 radiator upper supports.

I17968
CO±18
± COOLINGRADIATOR AND CONDENSER MODULE
2001 PRIUS (RM778U)
8. REMOVE RADIATOR & CONDENSER MODULE
(a) Push the radiator & condenser module toward engine.
(b) Pull up the radiator until the lower radiator support is re-
moved.
(c) Pull it downward to remove it.

CO149±01
I17963
I17964
CO±22
± COOLINGELECTRIC COOLING FAN
2001 PRIUS (RM778U)
REMOVAL
1. DISCHARGE REFRIGERANT FROM REFRIGERATION
SYSTEM
HINT:
At the time of installation, please refer to the following item.
Evacuate air from refrigeration system.
Charge system with refrigerant and inspect for leakage of refrig-
erant.
Specified amount: 500 ± 50 g (17.64 ± 1.76 oz.)
2. DRAIN ENGINE COOLANT FROM RADIATOR
HINT:
It is not necessary to drain out all coolant.
3. REMOVE BRACKETS
(a) Remove the water hose from fan shroud.
(b) Remove the 5 bolts and 2 brackets.
4. REMOVE SUCTION AND DISCHARGE HOSES
(a) Remove the 2 bolts and disconnect the both hoses.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
HINT:
At the time of installation, please refer to the following item.
Lubricate 2 new O±rings with compressor oil and install them
to the tubes.
(b) Loosen the 2 nuts and remove the both hoses.
Torque:
Suction hose 32 N´m (330 kgf´cm, 24 ft´lbf)
Discharge hose 22 N´m (225 kgf´cm, 16 ft´lbf)
HINT:
At the time of installation, please refer to the following item.
Lubricate 2 new O±rings with compressor oil and install them
to the tubes.

B00319
Recommended Oil Viscosity (SAE):
10W ± 30
5W ± 30 PREFERRED
TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE100
38 80 60
27 40
16 0
±720
4 ±18 ±20
±29
°C °F
LU02K±08
B11764
Oil Pressure
Switch
B11765
Oil Pressure Gauge
± LUBRICATIONOIL AND FILTER
LU±1
1307 Author: Date:
2001 PRIUS (RM778U)
OIL AND FILTER
INSPECTION
1. CHECK ENGINE OIL QUALITY
Check the oil for deterioration, entry of water, discoloring or thin-
ning.
If the quality is visibly poor, replace the oil.
Oil grade:
API grade or SJ, Energy±Conserving or ILSAC multi-
grade engine oil is recommended. SAE 5W±30 is the
best choice for your vehicle, for good fuel economy,
and good starting in cold weather.
2. CHECK ENGINE OIL LEVEL
After warming up the engine and then 5 minutes after the en-
gine stop, oil level should be between the ºLº and ºFº marks on
the dipstick.
If low. check for leakage and add oil up to the ºFº mark.
NOTICE:
Do not fill with engine oil above the ºFº mark.
3. REMOVE OIL PRESSURE SWITCH, AND INSTALL OIL
PRESSURE GAUGE
(a) Remove the oil pressure switch.
(b) Install the oil pressure gauge.
4. ACTIVATE INSPECTION MODE AND WARM UP EN-
GINE (See page IN±10)
Allow the engine to warm up to normal operating temperature.
5. CHECK OIL PRESSURE
Oil pressure:
At idle speed
29 kPa (0.3 kgf/cm
2, 4.3 psi) or more
At 2,250 rpm
150 ± 550 kPa (1.5 ± 5.6 kgf/cm
2, 22 ± 80 psi)
6. REMOVE OIL PRESSURE GAUGE AND REINSTALL
OIL PRESSURE SWITCH
(a) Remove the oil pressure gauge.

P12478
Adhesive
LU±2
± LUBRICATIONOIL AND FILTER
1308 Author: Date:
2001 PRIUS (RM778U)
(b) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833±00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(c) Install the oil pressure switch.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
7. START ENGINE AND CHECK FOR LEAKS

LU02M±08
A13942
Wiper Arm
VSV for EVAPAir Cleaner
Assembly
RH Engine Mounting
Insulator
Engine Under
Cover RH
N´m (kgf´cm, ft´lbf) : Specified torqueOuter Front Cowl
Top Panel
26 (265, 19)
52 (530, 38)
60 (612, 44)
52 (530, 38)
Air Inlet
Engine Coolant
Reservoir TankBrake reservoir
Tank
Wiper Motor and
Wiper Link
AssemblyHeat to Cowl Top
Seal
Cowl Top Ventilator
Lower LH Cowl Top Ventilator
Lower LH
R/B (ABS)
26 (265, 19)
7 (71, 62 in. lbf)
LU±4
± LUBRICATIONOIL PUMP
1310 Author: Date:
2001 PRIUS (RM778U)
OIL PUMP
COMPONENTS

A13926
RH Engine Mounting Bracket
Timing Chain Cover
Cylinder Head Cover

Crankshaft Front Oil Seal
Gasket
Water Pump Crankshaft Pulley
PCV Hose
N´m (kgf´cm, ft´lbf) : Specified torque

Non±reusable part
Water Pump Pulley
Ignition Coil
(w/ Ignitor)


O±Ring


O±Ring
15 (150, 11)
11 (110, 8)
15 (150, 11)


Gasket
Pin128 (1,300, 94)
± LUBRICATIONOIL PUMP
LU±5
1311 Author: Date:
2001 PRIUS (RM778U)

IG0EP±07
± IGNITIONIGNITION SYSTEM
IG±1
1318 Author: Date:
2001 PRIUS (RM778U)
IGNITION SYSTEM
ON±VEHICLE INSPECTION
NOTICE:
ºColdº and ºHotº in these sentences express the tempera-
ture of the coils themselves. ºColdº is from ±10°C (14°F) to
50°C (122°F) and ºHotº is from 50°C (122°F) to 100°C
(212°F).
1. INSPECT IGNITION COIL (WITH IGNITER) AND
SPARK TEST
Check that the spark occurs.
(1) Remove the ignition coils (with igniter) (See page
IG±6).
(2) Using a 16 mm (0.63 in.) plug wrench, remove the
spark plugs.
(3) Install the spark plugs to each ignition coils (with ig-
niter), and connect the ignition coil connectors.
(4) Disconnect the 4 injector connectors.
(5) Ground the spark plugs.
(6) Check if spark occurs while engine is being
cranked.
NOTICE:
To prevent gasoline from being injected from injectors dur-
ing this test, crank the engine for no more than 5 ± 10 se-
conds at time.

B11758
B11759
IG±4
± IGNITIONIGNITION SYSTEM
1321 Author: Date:
2001 PRIUS (RM778U)
4. INSPECT CRANKSHAFT POSITION SENSOR
(a) Remove the engine under cover RH.
(b) While sliding the connector lock, remove the connector.
(c) Using an ohmmeter, measure the resistance between the
terminals.
Resistance:
Cold985 ± 1,600 W
Hot1,265 ± 1,890 W
If the resistance is not as specified, replace the crankshaft posi-
tion sensor.
(d) Install the connector.
(e) Install the engine under cover RH.