engine TOYOTA PRIUS 2001 Service Repair Manual

HT003±01
D09721
D09722
D09723O±Ring
D09724
± HYBRID TRANSAXLEOIL PUMP ASSEMBLY
HT±3
1376 Author: Date:
2001 PRIUS (RM778U)
OIL PUMP ASSEMBLY
ON±VEHICLE REPAIR
1. REMOVE ENGINE UNDER COVER LH
2. REMOVE OIL PUMP
(a) Remove the plug.
(b) Remove the O±ring from the plug.
(c) Remove the 5 bolts and oil pump cover.
(d) Remove the O±ring.
(e) Remove the oil pump driven rotor and drive rotor.

D09725
D09724
D09723
O±Ring
D09722
D09721
HT±4
± HYBRID TRANSAXLEOIL PUMP ASSEMBLY
1377 Author: Date:
2001 PRIUS (RM778U)
(f) Remove the oil pump drive shaft.
3. INSTALL OIL PUMP
(a) Apply ATF to each sliding part.
(b) Install the oil pump drive shaft.
(c) Install the oil pump driven rotor and drive rotor.
(d) Install a new O±ring.
(e) Apply liquid sealer to 2 or 3 threads of the bolt end.
Sealant:
Part No. 08833±00080, THREE BOND 1344, LOCTITE
242 or equivalent
(f) Install the oil pump cover with the 5 bolts.
Torque: 5.5 N´m (56 kgf´cm, 49 in.´lbf)
(g) Install a new O±ring and the plug.
Torque: 7.35 N´m (75 kgf´cm, 65 in.´lbf)
4. INSTALL ENGINE UNDER COVER LH

HT00B±01
D09694
D09695
D09696
HT±14
± HYBRID TRANSAXLEHYBRID TRANSAXLE ASSEMBLY
2001 PRIUS (RM778U)
DISASSEMBLY
1. INSTALL ENGINE HUNGER
Install the engine hanger onto the MG1 side as shown in the il-
lustration, and lift it up by a chain device.
Engine hanger part No.:
12281±67070, S1228±11781
Bolt part No.:
91642±81045
91642±81265 2 pieces
Nut part No.:
90178±10001
90179±12147 2 pieces
NOTICE:

As the transaxle itself is heavy, place a wood block
underneath to stabilize it and carry out the operation
carefully.

Do not pull or bend the high±voltage cable of the MG1
assembly.

Drain the fluid before disassembly.
2. REMOVE MG1 ASSEMBLY
(a) Remove the 21 bolts.
(b) Using a screwdriver and a hammer, disconnect the MG1
assembly from the MG2 assembly.

D09857
D09694
D09695
D09858
SST
± HYBRID TRANSAXLEHYBRID TRANSAXLE ASSEMBLY
HT±29
2001 PRIUS (RM778U)
10. INSTALL DIFFERENTIAL TO MG2 ASSEMBLY
(a) Install the differential assembly to the MG2 assembly.
HINT:
Apply ATF to the side bearing.
(b) Install the engine hanger onto the MG1 side as shown in
the illustration, and lift it up by a chain device.
Engine hanger part No.:
12281 ± 67070, S1228 ± 11781
Bolt part No.:
91642 ± 81045
91642 ± 81265 2 pieces
Nut part No.:
90178 ± 10001
90179 ± 12147 2 pieces
(c) Install the 13 bolts and MG1 assembly to the MG2 assem-
bly.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
(d) Using SST, rotate the differential case assembly in both
directions to make it fit.
SST 09564±32011

D09860
D09694
D09695
D09858
SST
± HYBRID TRANSAXLEHYBRID TRANSAXLE ASSEMBLY
HT±31
2001 PRIUS (RM778U)
(b) Install the counter driven gear to the MG2 assembly.
HINT:
Apply ATF to the side bearing.
(c) Install the engine hanger onto the MG1 side as shown in
the illustration, and lift it up by a chain device.
Engine hanger part No.:
12281 ± 67070, S1228 ± 11781
Bolt part No.:
91642 ± 81045
91642 ± 81265 2 pieces
Nut part No.:
90178 ± 10001
90179 ± 12147 2 pieces
(d) Install the MG1 assembly to the MG2 assembly with the
13 bolts.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
(e) Using SST, rotate the differential case assembly in both
directions to make it fit.
SST 09564±32011

F12941
F11576
SST
F11617
F12941
SA±10
± SUSPENSION AND AXLEFRONT AXLE HUB
2001 PRIUS (RM778U)
5. LOOSEN 2 NUTS ON LOWER SIDE OF SHOCK AB-
SORBER
Torque: 153 N´m (1,560 kgf´cm, 113 ft´lbf)
HINT:
Do not remove the 2 bolts and nuts.
6. DISCONNECT TIE ROD END FROM STEERING
KNUCKLE
(a) Remove the cotter pin and nut.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
HINT:
At the time of installation, if the holes for a new cotter pin are not
aligned, tighten the nut further up to 60°.
(b) Using SST, disconnect the tie rod end from the steering
knuckle.
SST 09628±62011
7. DISCONNECT LOWER SUSPENSION ARM FROM
LOWER BALL JOINT
Remove the 2 nuts and bolt.
Torque: 142 N´m (1,450 kgf´cm, 105 ft´lbf)
8. REMOVE STEERING KNUCKLE WITH AXLE HUB
(a) Remove the 2 bolts and nuts on the lower side of the
shock absorber.
HINT:
At the time of installation, coat the nut's thread with engine oil.
(b) Remove the steering knuckle with the axle hub.
NOTICE:
Be careful not to damage the boot and ABS speed sensor
rotor.

SA20B±01
FA1535
SST
F12940SST
F11576
SST
± SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA±17
2001 PRIUS (RM778U)
REMOVAL
NOTICE:

The hub bearing could be damaged if it is subjected
to the vehicle weight, such as when moving the ve-
hicle with the drive shaft removed.
Therefore, if it is absolutely necessary to place the ve-
hicle weight on the hub bearing, first support it with
the SST.
SST 09608±16042 (09608±02021, 09608±02041)

After disconnecting the drive shaft from the axle hub,
work carefully so as not to damage the ABS speed
sensor rotor serrations on the drive shaft.
1. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. REMOVE ENGINE UNDER COVER
3. DRAIN ATF
4. REMOVE DRIVE SHAFT LOCK NUT
(a) Using SST and a hammer, unstake the staked part of the
lock nut.
SST 09930±00010
(b) While applying the brakes, remove the nut.
Torque: 216 N´m (2,200 kgf´cm, 159 ft´lbf)
5. DISCONNECT TIE ROD END FROM STEERING
KNUCKLE
(a) Remove the cotter pin and nut.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
HINT:
At the time of installation, if the holes for a new cotter pin are not
aligned, tighten the nut further up to 60°.
(b) Using SST, disconnect the tie rod end from the steering
knuckle.
SST 09628±62011

SA1ZW±01
F11576
SST
F11616
F11617
F11586
± SUSPENSION AND AXLEFRONT LOWER SUSPENSION ARM
SA±33
2001 PRIUS (RM778U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. REMOVE ENGINE UNDER COVER
3. REMOVE LOWER SUSPENSION ARM
(a) Disconnect the RH and LH tie rod ends.
(1) Remove the cotter pin and nut.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
(2) Using SST, disconnect the tie rod end from the
steering knuckle.
SST 09628±62011
(3) Employ the same manner described above to the
other side.
(b) Disconnect the RH and LH stabilizer bar links.
(1) Remove the nut and disconnect the stabilizer bar
link from the shock absorber.
Torque: 74 N´m (755 kgf´cm, 55 ft´lbf)
HINT:
If the ball joint turns together with the nut, use a hexagon (5 mm)
wrench to hold the stud.
(2) Employ the same manner described above to the
other side.
(c) Disconnect the RH and LH lower suspension arms from
the lower ball joints.
(1) Remove the bolt and 2 nuts, and disconnect the
lower suspension arm from the lower ball joint.
Torque: 142 N´m (1,450 kgf´cm, 105 ft´lbf)
(2) Employ the same manner described above to the
other side.
(d) Loosen the 2 lower suspension arm set bolts.
Torque: 137 N´m (1,397 kgf´cm, 101 ft´lbf)
HINT:
At the time of installation, after stabilizing the suspension,
torque the bolts.
(e) Disconnect the sliding yoke (See page SR±6).
(f) Support the suspension member with a transmission
jack.

± BRAKETROUBLESHOOTING
BR±3
1518 Author: Date:
2001 PRIUS (RM778U) Noise from brakes
1. Pad or lining (Cracked or distorted)
2. Installation bolt (Loose)
3. Disc or drum (Scored)
4. Pad support plate (Loose)
5. Sliding pin (Worn)
6. Pad or lining (Dirty)
7. Pad or lining (Glazed)
8. Tension or return spring (Faulty)
9. Anti±squeal shim (Damaged)
10.Shoe hold±down spring (Damaged)BR±23
BR±32
BR±26
BR±26
BR±32
BR±23
BR±26
BR±23
BR±32
BR±23
BR±32
BR±32
BR±23
BR±32
Brake warning light lights up*1
(Parking brake pedal released)
1. Brake fluid level
2. Hydraulic brake booster power supply system (Faulty)
BR±41
Brake warning light lights up and brake warning buzzer sounds*2Hydraulic brake booster power supply system (Faulty)BR±41
ABS warning light lights up*31. Anti±lock brake system (Faulty)
2. Hydraulic brake booster power supply system (Faulty)
BR±41
*1, *3: The light may stay on for about 60 seconds after the engine has been started. It is normal if it goes
out after a while.
*
2, *3: Depressing the brake pedal repeatedly may turn on the warning light and buzzer. It is normal if the
light goes out and the buzzer stops sounding after a few seconds.

BR1JF±01
F12415
Wiper Arm
Cowl Top Ven-
tilator Louver
LH
Hood to Cowl Top Seal
Wiper Motor & Link Assembly
Outer Front Cowl Top Panel
Converter and Inverter
Assembly
Front Door Scuff PlateLower Finish Panel Cowl Top Ventilator Louver RH
Finish Panel Engine Room
R/B No. 2

Gasket Clip
Cowl Side Trim
13 (130, 9)
Clevis PinWave Washer
Clip
Return Spring
Circuit Breaker
SensorMG 2
MG 1
20 (204, 15)
8.0 (82, 71 in.´lbf)
Clip
Lithium soap base glycol grease: Specified torque
N´m (kgf´cm, ft´lbf)

Non±reusable part
Reservoir Hose
Master Cylinder Reservoir Hose
8.0 (82, 71 in.´lbf)
8.0 (82, 71 in.´lbf)
Inverter Terminal
Cover

Gasket
Hood Lock Release
Lever
Connector Cover
Wiper Motor Cover
21 (214, 15)
26 (270, 20)
7.4 (75, 64 in.´lbf)
5.4 (55, 48 in.´lbf)
15 (155, 11)
21 (214, 15)
BR±16
± BRAKEBRAKE MASTER CYLINDER
1531 Author: Date:
2001 PRIUS (RM778U)
BRAKE MASTER CYLINDER
COMPONENTS