drain bolt TOYOTA PRIUS 2001 Service Repair Manual

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

SS1HF±01
± SERVICE SPECIFICATIONSHYBRID TRANSAXLE
SS±25
2001 PRIUS (RM778U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Oil pump cover x MG2 assembly5.55649 in.´lbf
Transaxle oil drain plug4949836
Hybrid transaxle assembly x Engine3333224
Coolant drain plug x MG1 assembly3940029
Screw plug x MG1 assembly12.71309
Screw plug x MG2 assembly24.525018
Filler plug x MG2 assembly3940029
MG1 assembly x MG2 assembly2525018
Sleeve bracket x MG1 assembly131309
Lock clamp x MG1 assembly5.45548 in.´lbf
Oil strainer x MG2 assembly5.55649 in.´lbf
Oil pan x MG2 assembly7.67767 in.´lbf
Parking shaft cover x MG2 assembly1313010
Motor water jacket cover x MG2 assembly5.55649
Housing tube x MG1 assembly1515211
Detent spring set bolt101007
Parking cover x MG2 assembly5.55649 in.´lbf
Oil pump cover x plug7.357565 in.´lbf
Wiring harness connector x MG2 assembly5.55649 in.´lbf
Wiring harness connector x MG1 assembly5.55649 in.´lbf
Water jacket union5051037
High±voltage cable set bolt (3 under power cable cover)1818313
High±voltage cable set bolt (3 outside)5.55649 in.´lbf
Power cable cover x MG1 assembly4.84842 in.´lbf
Mounting bracket x MG2 assembly5253038
Shift lever assembly x Steering column88071 in.´lbf
Differential case x Ring gear879064

EM1IU±03
A13907
A13908
A13934
A13943
± ENGINE MECHANICALTIMING CHAIN
EM±15
2001 PRIUS (RM778U)
REMOVAL
1. DISCONNECT BATTERY NEGATIVE (±) TERMINAL
AND HV BATTERY SERVICE PLUG
(See page HV±1)
2. REMOVE OUTER FR COWL TOP PANEL ASSEMBLY
(See page BO±32)
3. REMOVE RH ENGINE UNDER COVER
4. DRAIN ENGINE COOLANT
5. REMOVE AIR CLEANER ASSEMBLY
(a) Disconnect the MAF meter connector.
(b) Disconnect the EVAP hose from the air cleaner case.
(c) Loosen the 2 hose clamps.
(d) Remove the 3 bolts and air cleaner assembly.
6. REMOVE BRAKE RESERVOIR TANK
(a) Disconnect the brake fluid level sensor connector.
(b) Remove the 2 bolts and remove the reservoir tank and
suspend it.
(c) Remove the 3 bolts and reservoir tank bracket.
7. DISCONNECT CONNECTORS
(a) Disconnect the 4 ignition connectors.
(b) Disconnect the 4 injector connectors.
(c) Disconnect the 2 VSV connectors.
(d) Disconnect the camshaft position sensor connector.
(e) Disconnect the water temperature connector.
(f) Disconnect the Camshaft timing oil control valve connec-
tor.
8. REMOVE AIR INLET
9. REMOVE ENGINE COOLANT RESERVOIR TANK
10. REMOVE VSV FROM ENGINE MOUNTING INSULA-
TOR
11. REMOVE DRIVE BELT

EM1IX±02
A13907
B11761
A13934
± ENGINE MECHANICALCYLINDER HEAD
EM±29
2001 PRIUS (RM778U)
REMOVAL
1. DISCONNECT BATTERY NEGATIVE (± )TERMINAL
AND HV BATTERY SERVICE PLUG
(See page HV±1)
2. REMOVE OUTER FRONT COWL TOP PANEL AS-
SEMBLY (See page BO±32)
3. DRAIN HV TRANSAXLE COOLANT
(See page HT±6)
4. DRAIN ENGINE COOLANT
5. REMOVE CONVERTER AND INVERTER ASSEMBLY
(See page HV±18)
6. REMOVE AIR CLEANER ASSEMBLY
(a) Disconnect the MAF meter connector.
(b) Disconnect the EVAP hose from the air cleaner case.
(c) Loosen the 2 hose clamps.
(d) Remove the 3 bolts and air cleaner assembly.
7. REMOVE IGNITION COILS (See page IG±6)
8. REMOVE SPARK PLUGS (See page IG±1)
9. REMOVE PCV HOSES
10. REMOVE THROTTLE BODY (See page SF±28)
11. DISCONNECT ENGINE WIRE FROM CYLINDER HEAD
(a) Disconnect the ECT sensor connector.
(b) Disconnect the camshaft position sensor connector.
(c) Disconnect the oil control valve connector.
(d) Disconnect the 4 injector connectors.
(e) Remove the 3 bolts and disconnect the engine wire pro-
tector from the cylinder head cover.

EM1J0±02
A13907
A13943
± ENGINE MECHANICALENGINE UNIT
EM±53
2001 PRIUS (RM778U)
REMOVAL
1. DISCONNECT BATTERY NEGATIVE (±) TERMINAL
AND HV BATTERY SERVICE PLUG
(See page HV±1)
2. REMOVE OUTER FRONT COWL TOP PANEL AS-
SEMBLY (See page BO±32)
3. DRAIN HV COOLANT (See page HT±8)
4. DRAIN ENGINE COOLANT
5. REMOVE CONVERTER AND INVERTER ASSEMBLY
(See page HV±18)
6. REMOVE HEATER UNIT WATER PUMP
(See page AC±55)
7. REMOVE AIR CLEANER ASSEMBLY
(a) Disconnect the MAF meter connector.
(b) Disconnect the EVAP hose from the air cleaner case.
(c) Loosen the 2 hose clamps.
(d) Remove the 2 bolts and air cleaner assembly.
8. DISCONNECT CONNECTORS, CLAMPS AND HOSES
(a) Disconnect the engine wire clamps.
(b) Disconnect the heated oxygen sensor connector.
(c) Disconnect the 2 power steering connectors.
(d) Disconnect the VSV connector for purge line.
(e) Disconnect the VSV hose for purge line.
(f) Disconnect the ground strap from RH fender apron.
(g) Disconnect the ground strap from LH fender apron.
9. REMOVE AIR INLET
10. REMOVE ENGINE COOLANT RESERVOIR TANK
11. DISCONNECT 2 RADIATOR HOSES FROM RADIATOR
12. DISCONNECT HEATER HOSE FROM CYLINDER
BLOCK

EM17C±04
A10451
A11268
A11269
A14342
EM±64
± ENGINE MECHANICALCYLINDER BLOCK
2001 PRIUS (RM778U)
DISASSEMBLY
1. INSTALL ENGINE TO ENGINE STAND FOR
DISASSEMBLY
2. REMOVE TIMING CHAIN (See page EM±15)
3. REMOVE CYLINDER HEAD
(See page EM±29)
4. REMOVE ENGINE WIRE
5. REMOVE WATER BYPASS PIPE
Remove the 2 nuts, bolt and water bypass pipe.
6. REMOVE THERMOSTAT
(See page CO±10)
7. REMOVE KNOCK SENSOR (See page SF±56)
8. REMOVE OIL PRESSURE SWITCH
(See page LU±1)
9. REMOVE ENGINE COOLANT DRAIN UNION
10. REMOVE OIL FILTER
(See page LU±3)
11. REMOVE OIL FILTER UNION
Using a 12 mm hexagon wrench, remove the oil filter union.
12. REMOVE OIL PAN NO. 2
(a) Remove the 9 bolts and 2 nuts.
(b) Insert the blade of SST between the oil pan No. 1 and oil
pan No. 2, and cut off applied sealer and remove the oil
pan.
SST 09032±00100
NOTICE:

Be careful not to the damage the oil pan contact sur-
face of the oil pan No. 1.

Be careful not to damage the oil pan No. 2 flange.
13. REMOVE OIL STRAINER
Remove the bolt and 2 nuts, oil strainer and gasket.

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.

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.

HV00A±01
B11977
B11979
B11980
HV±18
± HYBRID VEHICLE CONTROLCONVERTER AND INVERTER ASSEMBLY
2001 PRIUS (RM778U)
REMOVAL
1. REMOVE SERVICE PLUG (See page HV±1)
2. DRAIN HV COOLANT (See page HT±6)
3. REMOVE COWL TOP PANEL (See page BO±31)
4. VERIFY 0 V
NOTICE:

Before starting step (a), 5 minutes or more should be
passed after removing the service plug.

Be careful to prevent foreign matter from entering the
inside of connector cover.
(a) Disconnect the connector of the battery power cable and
insulate it with packaging tape.
(b) Using a torx socket wrench (T30), remove the 4 screws
and inverter terminal cover.
(c) Using a torx socket wrench (T40), remove the 2 screws,
circuit breaker sensor and connector cover.
HINT:
Slide the connector cover to disconnect the circuit breaker sen-
sor connector.
(d) Using a voltmeter, measure the voltage between termi-
nals of 3 phases (U±V, V±W, U±W) and each terminal and
body ground to verify them to be approx. 0 V.
5. REMOVE CONVERTER & INVERTER ASSEMBLY
(a) Remove the 6 bolts and 3 power cables for MG2.
NOTICE:
Be careful to prevent foreign matter from entering the in-
side of connector cover.
(b) Remove the 3 bolts and power cable for MG1.
NOTICE:

Remove the power cable for MG1 together with con-
verter & inverter assembly.

Be careful to prevent foreign matter from entering the
inside of connector cover.
(c) Remove the bolt and ground cable.