cylinder bolt TOYOTA PRIUS 2001 Service Repair Manual

CHASSIS ± BRAKES
165CH33
Wheel Cylinder
Adjusting Bolt
Shoe
Strut
Auto
Adjust
Lever
Spring
A
C D
B
182CH41
PawlPawl SpringRelease
Intermediate
Lever
Sector
Parking Brake
Cable 102
Incremental Type Hydraulic Auto Adjuster
Ordinarily, when the rear brakes are applied, the
shoes expand until they come in contact with the
inner surface of the drum.
While the auto adjust lever remains in contact
with point A of the strut, the spring force causes
the auto adjust lever to rotate in direction C, with
adjust lever point B as the fulcrum. At this time,
if the shoe clearance exceeds a predetermined
amount, the tip of the auto adjust lever rotates the
adjusting bolt in direction D by 1 tooth, causing
the strut to move for a predetermined amount to-
wards the direction that expands the shoes. As a
result, by pushing and expanding the initial posi-
tion of the shoes, an appropriate amount of clear-
ance is maintained between the shoes and the
drum.
PARKING BRAKE
1. General
On the Prius uses a pedal type parking brake that is released by pressing the pedal further.
2. Construction
A pedal type parking brake pedal consists mainly
of a parking brake pedal, sector, pawl, release in-
termediate lever, pawl spring and pedal return
spring.
The parking brake pedal and sector are integrated,
and parking brake cable is attached to the parking
brake pedal.
The pawl and the release intermediate lever are
linked by the pawl spring and operate together
along with the movement of the pedal.

PP2FC±02
± PREPARATIONENGINE MECHANICAL
PP±5
2001 PRIUS (RM778U)
EQUIPMENT
Abrasive compoundValve
Caliper gauge
CO/HC meter
Compression gauge
Connecting rod aligner
Cylinder gauge
Dial indicator
Dye penetrant
Engine tune±up tester
Groove cleaning toolPiston ring groove
Heater
Magnetic finger
Micrometer
Pin hole grinderPiston pin hole of piston
Piston ring compressor
Piston ring expander
Plastigage
Precision straight edge
Press
Ridge reamerCylinder
Soft brush
Solvent
Spring testerValve spring
Steel squareValve spring
Thermometer
Torque wrench
Torx wrench socket setStud bolt
TOYOTA hand held tester or OBDII scan tool
Valve seat cutter
V±block
Vernier calipers
Wire brushValve

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.)

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

SS179±02
± SERVICE SPECIFICATIONSLUBRICATION
SS±17
2001 PRIUS (RM778U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Oil pressure switch x Cylinder block131309
Oil drain plug x Oil pan3838728
Plug x Oil pump body2525518
Oil pump cover x Timing chain cover Bolt
Screw8.8
10.390
10578 in.´lbf
8

SS0LN±06
± SERVICE SPECIFICATIONSBRAKE
SS±29
2001 PRIUS (RM778U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
BRAKE PEDAL
Pedal bracket x Reinforcement1414310
Brake pedal x Pedal bracket3737527
PARKING BRAKE PEDAL
Pedal bracket x Reinforcement1414310
Pedal bracket x Body131309
Brake pedal x Pedal bracket3232724
BRAKE MASTER CYLINDER
Master cylinder x Pedal bracket131309
Master cylinder clevis lock nut2626519
HYDRAULIC BRAKE BOOSTER
Hydraulic brake booster assembly x Body1919414
Sub±bracket x Body1919414
Reservoir bracket x Body1818413
Reservoir x Bracket7.57766 in.´lbf
Accumulator x Booster pump5455036
Pressure switch assembly x Brake power supply bracket7.88069 in.´lbf
Booster pump x Brake booster pump bracket No. 27.88069 in.´lbf
Pressure switch assembly x Brake booster pump bracket No. 17.88069 in.´lbf
Connector bracket x Pressure switch assembly7.88069 in.´lbf
Pressure switch assembly x Brake booster pump bracket No. 27.88069 in.´lbf
FRONT BRAKE
Front disc brake caliper installation bolt3435025
Bleeder plug8.38574 in.´lbf
Front disc brake caliper x Flexible hose3031022
Front disc brake torque plate x Steering knuckle1071,09079
REAR BRAKE
Bleeder plug8.58775 in.´lbf
Rear drum brake wheel cylinder x Backing plate101007
BRAKE ACTUATOR
Brake actuator assembly x Body1919514
Brake actuator x Actuator bracket111208
SPEED SENSOR
Front speed sensor installation bolt8.08271 in.´lbf
Front speed sensor harness clamp bolt5.55649 in.´lbf
Rear speed sensor harness clamp bolt5.55649 in.´lbf
BRAKE LINE
Brake line union nut1515511

A11252Matchmarks
A10471
EM±6
± ENGINE MECHANICALVALVE CLEARANCE
1122 Author: Date:
2001 PRIUS (RM778U)
4. ADJUST VALVE CLEARANCE
(a) Set the No.1 cylinder to the TDC/compression (See pro-
cedure in step 2).
(b) Place matchmarks on the timing chain and camshaft tim-
ing sprockets.
(c) Remove the 2 plug from the timing chain cover.
(d) Using drivers or equipment, while rotating the stopper
plate of the tensioner downward, turn the exhaust cam-
shaft right a little and push in the plunger of the chain ten-
sioner as shown in the illustration.
HINT:
When the stopper plate cannot be lowered easily, rotate the ex-
haust camshaft right and left a little.
(e) Insert a bar of ù 2 ± 3 mm (0.08 ± 0.12 in.) into the holes
in the stopper plate and tensioner to fix the stopper plate.
HINT:

At this time, it is easier to fix by installing the bar while ro-
tate the camshaft right and left a little.

Fix the bar with tape so that the bar does not come off.
(f) Remove the timing chain from the camshaft timing
sprocket.
NOTICE:

Never rotate the crankshaft with the timing chain re-
moved.

When rotating the camshaft with the timing chain re-
moved, rotate the crankshaft counterclockwise 40°
from the TDC and align the oil jet hole with the paint
mark before rotating it.

When installing the timing chain, make sure to return
it to the position of the matchmarks for camshaft and
then rotate the crankshaft clockwise to return.
HINT:
When the chain cannot be removed easily, rotate the intake
camshaft right and left a little.
(g) Hold the hexagonal portion of the camshaft with a
wrench, and remove the bolt and valve timing controller
assembly with the chain.
NOTICE:
Do not disassembled the valve timing controller assembly.
(h) Remove the intake and exhaust camshaft assembly.
HINT:
When disconnect the timing chain from the camshaft timing
sprocket, holding the timing chain.

A13927
A13928
B11761
A11222
A11244
EM±16
± ENGINE MECHANICALTIMING CHAIN
2001 PRIUS (RM778U)
12. REMOVE RH ENGINE MOUNTING INSULATOR
(a) Set the jack to the engine.
HINT:
Place the wooden block between the jack and engine.
(b) Remove the 5 bolts, 2 nuts and RH engine mounting insu-
lator.
13. DISCONNECT ENGINE WIRE FROM CYLINDER HEAD
COVER
Remove the 3 bolts and disconnect the engine wire from the cyl-
inder head.
14. REMOVE CYLINDER HEAD COVER
(a) Remove the ignition coils (See page IG±6)
(b) Remove the 2 PCV hoses from the cylinder head cover.
(c) Remove the 7 bolts, 2 seal washers, 2 nuts, cylinder head
cover and gasket.
15. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with timing
mark º0º of the timing chain cover.

A11245
Timing Marks
A11253
SST
SST
A11254
SST
A11258
A11255
± ENGINE MECHANICALTIMING CHAIN
EM±17
2001 PRIUS (RM778U)
(b) Check that both timing marks on the camshaft timing
sprocket and valve timing controller assembly are facing
right up as shown in the illustration.
If not, turn the crankshaft 1 revolution (360°) and align the
marks as above.
16. REMOVE CRANKSHAFT PULLEY
(a) Using SST, remove the pulley bolt.
SST 09213±70010, 09330±00021
(b) Remove the crankshaft pulley and pin.
HINT:
If necessary, remove the pulley with SST.
SST 09950±50012 (09951±05010, 09952±05010,
09953±05020, 09954±05020)
17. REMOVE CRANKSHAFT POSITION SENSOR
(See page IG±12)
18. REMOVE RH ENGINE MOUNTING BRACKET
Remove the 4 bolts and mounting bracket.
19. REMOVE WATER PUMP (See page CO±6)
20. REMOVE OIL CONTROL VALVE (See page EM±29)
21. REMOVE TIMING CHAIN COVER
(a) Remove the 13 bolts and nut.
(b) Using a torx wrench socket (E8), remove the stud bolt.
(c) Remove the timing chain cover by prying the portions be-
tween the cylinder head and cylinder block with a screw-
driver.
NOTICE:
Be careful not to damage the contact surfaces of the timing
chain cover, cylinder head and cylinder block.

EM±18
± ENGINE MECHANICALTIMING CHAIN
2001 PRIUS (RM778U)
(d) Remove the 2 O±rings from the cylinder block and oil pan
No.1.
22. REMOVE CHAIN TENSIONER
Remove the 2 bolts and chain tensioner.
23. REMOVE CHAIN TENSIONER SLIPPER
24. REMOVE CHAIN VIBRATION DAMPER
Remove the 2 bolts and damper.
25. REMOVE TIMING CHAIN