height TOYOTA PRIUS 2001 Service Repair Manual

NEW MODEL OUTLINE
INTERIOR
Easy-to-use luggage
compartment with ample space High point of vision for
easier understanding of
surrounding conditionsSpacious head clearance
for a more open feel
Ideal hip point height for easy access
182MO05
182MO06
Multi±Information Display
Meter
10
An interior which reflects the type of
comfort that will be regarded as a must in
cars hereinafter.
Package
The Prius package gives highest priority to driver and passenger
comfort.

A spacious cab that is hard to imagine in a car of this size.

Spacious head clearance for a more open feel.

Ideal seat height for easy access.

An easy-to-use luggage compartment with ample space.
Instrument Panel
The instrument panel is a balanced combination of functionality and
symmetry.

Human-engineered layout perfectly suited to the new age, with centrally positioned operational functions.

BODY ± AERODYNAMICS
182BO12
182BO13
Front Fairing Rear Fairing137
AERODYNAMICS
DESCRIPTION
To improve aerodynamic performance, the following measures have been taken.

The shapes of the front pillar, outside rear view mirror, and the front windshield glass have been optimized
to achieve a smooth air flow.

The height and the shape of the front bumper have been optimized in order to rectify the airflow under the
floor and along the body sides.

The shapes of the engine undercover, fuel tank bottom surface, and the rear floor bottom surface have been
optimized to achieve a smooth underbody air flow.

A front and rear fairings are provided to smooth out the airflow around the tires and reduce the air resis-
tance while the vehicle is in motion.

APPENDIX
5
10
15
20
25
30
35
40
45
50
55
60
65
70
Area
Item
Major Dimensions & Vehicle Weights Performance Engine Engine
Chassis
Electrical
192
MAJOR TECHNICAL SPECIFICATIONS
U.S.A. and CanadaBody Type4-Door SedanVehicle GradeÐModel CodeNHW11L-AEEEBANHW11L-AEEEBKLength mm (in.)4305 (169.5)u
OverallWidth mm (in.)1695 (66.7)uOverallHeight mm (in.)1465 (57.6)uWheel Base mm (in.)2550 (100.4)u
TreadFront mm (in.)1475 (58.1)uTreadRear mm (in.)1480 (58.3)u
Effective Head RoomFront mm (in.)985 (38.8)uEffective Head RoomRear mm (in.)942 (37.1)u
Effective Leg RoomFront mm (in.)1047 (41.2)uEffective Leg RoomRear mm (in.)899 (35.4)u
Shoulder RoomFront mm (in.)1342 (52.8)uShoulder RoomRear mm (in.)1325 (52.2)u
OverhangFront mm (in.)815 (32.1)uOverhangRear mm (in.)940 (37.0)uMin. Running Ground Clearance mm (in.)125 (4.9)uAngle of Approach degrees145uAngle of Departure degrees225uFront kg (lb)770 (1700)u
Curb WeightRear kg (lb)485 (1065)uCurb WeightTotal kg (lb)1255 (1765)uFront kg (lb)890 (1965)u
Gross Vehicle WeightRear kg (lb)750 (1650)uGross Vehicle WeightTotal kg (lb)1640 (3615)uFuel Tank Capacity
(US. gal., lmp.gal.)45* (11.9, 9.9)uLuggage Compartment Capacity m3 (cu.ft.)0.39 (137.7)uMax. Speed km/h (mph)160 (99.4)uMax. Cruising Speed km/h (mph)160 (99.4)u
Acceleration0 to 100 km/h sec.12.7uAcceleration0 to 400 m sec.19.0u1st Gear km/h (mph)ÐÐ
Max. Permissible2nd Gear km/h (mph)ÐÐMax. Permissible
Speed3rd Gear km/h (mph)ÐÐp
4th Gear km/h (mph)ÐÐ
Min. Turning RadiusWall to Wall m (ft.)10.2 (33.5)uMin. Turning Radius
(Outside Front)Curb to Curb m (ft.)9.4 (30.8)uEngine Type1NZ-FXEuValve Mechanism16-Valve, DOHCuBore y Stroke mm (in.)75.0 y 84.7 (2.95 y 3.33)uDisplacement cm3 (cu.in.)1497 (91.4)uCompression Ratio13.0uCarburetor TypeSFIuResearch Octane No. RON95uMax. Output (EEC) kW/rpm (HP@rpm)52/4500 (70@4500)uMax. Torque (EEC) N´m/rpm (lb-ft@rpm)111/4200 (82@4200)uBattery Capacity (5HR) Voltage & Amp. Hr.12 ± 28uAlternator Output WattsÐÐStarter Output kWÐÐClutch TypeÐÐTransaxle TypeP111uIn FirstÐÐIn SecondÐÐ
Transmission GearIn ThirdÐÐTransmission Gear
RatioIn FourthÐÐIn FifthÐÐIn ReverseÐÐCounter Gear RatioÐÐDifferential Gear Ratio (Final)3.905u
Brake TypeFrontVentilated DiscuBrake TypeRearL.T. DrumuParking Brake TypeL.T. DrumuBrake Booster Type and Size in.HydraulicuProportioning Valve TypeP-Valveu
Suspension TypeFrontMacPherson StrutuSuspension TypeRearTorsion Beanu
Stabilizer BarFrontSTDuStabilizer BarRearSTDuSteering Gear TypeRack and PinionuSteering Gear Ratio (Overall)16.4~18.3uPower Steering TypeElectric Motoru
*: EPA / CARB ORVR Test conditions

IN04Q±11
IN±46
± INTRODUCTIONTERMS
46 Author: Date:
2001 PRIUS (RM778U)
TERMS
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti±Lock Brake System
ACAlternating Current
ACCAccessory
ACISAcoustic Control Induction System
ACSDAutomatic Cold Start Device
A.D.D.Automatic Disconnecting Differential
A/FAir±Fuel Ratio
AHCActive Height Control Suspension
ALRAutomatic Locking Retractor
ALTAlternator
AMPAmplifier
ANTAntenna
APPROX.Approximately
A/TAutomatic Transmission (Transaxle)
AT FAutomatic Transmission Fluid
AUTOAutomatic
AUXAuxiliary
AV GAverage
AV SAdaptive Variable Suspension
BABrake Assist
BACSBoost Altitude Compensation System
BATBattery
BDCBottom Dead Center
B/LBi±Level
B/SBore±Stroke Ratio
BTDCBefore Top Dead Center
BVSVBimetallic Vacuum Switching Valve
Calif.California
CBCircuit Breaker
CCoCatalytic Converter For Oxidation
CDCompact Disc
CFCornering Force
CGCenter Of Gravity
CHChannel
COMB.Combination
CPECoupe
CPSCombustion Pressure Sensor
CPUCentral Processing Unit
CRSChild Restraint System
CTRCenter
C/VCheck Valve
CVControl Valve

IN±48
± INTRODUCTIONTERMS
48 Author: Date:
2001 PRIUS (RM778U) H/B
Hatchback
H±FUSEHigh Current Fuse
HIHigh
HIDHigh Intensity Discharge (Head Lamp)
HSGHousing
HTHard Top
HVHybrid Vehicle
HWSHeated Windshield System
IACIdle Air Control
ICIntegrated circuit
IDIIndirect Diesel Injection
IFSIndependent Front Suspension
IGIgnition
IIAIntegrated Ignition Assembly
INIntake (Manifold, Valve)
INTIntermittent
I/PInstrument Panel
IRSIndependent Rear Suspension
J/BJunction Block
J/CJunction Connector
KDKick±Down
LANLocal Area Network
LBLiftback
LCDLiquid Crystal Display
LEDLight Emitting Diode
LHLeft±Hand
LHDLeft±Hand Drive
L/H/WLength, Height, Width
LLCLong±Life Coolant
LNGLiquified Natural Gas
LOLow
LPGLiquified Petroleum Gas
LSDLimited Slip Differential
LSP & PVLoad Sensing Proportioning And Bypass Valve
LSPVLoad Sensing Proportioning Valve
MAX.Maximum
MG1Motor Generator No. 1
MG2Motor Generator No. 2
MICMicrophone
MILMalfunction Indicator Lamp
MIN.Minimum
MPMultipurpose
MPXMultiplex Communication System
M/TManual Transmission
MTMount
MTGMounting

MA048±01
S01303
Dust Cover
± MAINTENANCECHASSIS
MA±7
60 Author: Date:
2001 PRIUS (RM778U)
CHASSIS
INSPECTION
1. INSPECT STEERING LINKAGE
(a) Check the steering wheel freeplay. (See page SR±3)
(b) Check the steering linkage for looseness or damage.
Check that:

Tie rod ends do not have excessive play.

Dust seals and boots are not damaged.

Boot clamps are not loose.
2. INSPECT SRS AIRBAG (See page RS±2)
3. INSPECT STEERING GEAR HOUSING OIL
Check the steering gear housing for oil leakage.
4. INSPECT DRIVE SHAFT BOOTS
Check the drive shaft boots for clamp looseness, leakage or
damage.
5. INSPECT BALL JOINTS AND DUST COVERS
(a) Inspect the ball joints for excessive looseness.

Jack up the front of the vehicle and place wooden
blocks with a height of 180 ± 200 mm (7.09 ± 7.87
in.) under the front tires.

Lower the jack until there is about half a load on the
front coil spring. Place stands under the vehicle for
safety.

Check that the front wheels are pointing straight
ahead, and block them with chocks.

Using a lever, pry up the end of the lower arm, and
check the amount of play.
Maximum ball joint vertical play: 0 mm (0 in.)
If there is play, replace the ball joint.
(b) Check the dust cover for damage.
6. CHECK TRANSAXLE OIL (FLUID)
Visually check the transaxle for oil (fluid) leakage.
If leakage is found, check for the cause and repair.
7. REPLACE TRANSAXLE OIL (FLUID)
Replace the transaxle oil (See page HT±26).

± 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.)

SS13W±06
SS±26
± SERVICE SPECIFICATIONSSUSPENSION AND AXLE
148 Author: Date:
2001 PRIUS (RM778U)
SUSPENSION AND AXLE
SERVICE DATA
Cold tire inflation
pressureTire size: P175/65R14 84S Front
Rear240 kPa (2.4 kgf/cm2, 35 psi)
230 kPa (2.3 kgf/cm2, 33 psi)
Vehicle height
P175/65R14Front*1
Rear*2191 mm (7.52 in.)
239 mm (9.41 in.)
Camber
Right±left error±0°26' ± 45' (±0.43° ± 0.75°)
45' (0.75°) or less
Front wheel
Caster
Right±left error1°02' ± 45' (1.03° ± 0.75°)
45' (0.75°) or less
Front wheel
alignmentSteering axis inclination
Right±left error9°52' ± 45' (9.87° ± 0.75°)
45' (0.75°) or less
Toe±in (total)
Rack end length difference0°06' ± 12' (0.1° ± 0.2°, 1 ± 2 mm, 0.04± 0.08 in.)
1.5 mm (0.059 in.) or less
Wheel angle
Inside wheel
Outside wheel: Reference
42°42' ± 2° (42.70° ± 2°)
35°54' (35.90°)
Rear wheel
Camber
Right±left error±1°30' ± 45' (±0.93° ± 0.75°)
45' (0.75°) or less
Rear wheel
alignmentToe±in (total)0°06' ± 20' (0.1° ± 0.33°)
1 ± 3.0 mm (0.04 ± 0.12 in.)
FtlAxle bearing backlash Maximum0.05 mm (0.0020 in.)Front axleAxle hub deviationMaximum0.07 mm (0.0028 in.)
Front drive shaftDrive shaft standard length LH
RH579.9 ± 5.0 mm (22.831 ± 0.197 in.)
836.9 ± 5.0 mm (32.949 ± 0.197 in.)
Ft iLower suspension arm ball joint turning torque1.0 ± 4.9 N´m (10 ± 50 kgf´cm, 8.7 ± 43 in.´lbf)Front suspensionStabilizer bar link ball joint turning torque0.05 ± 1.0 N´m (0.5 ± 10 kgf´cm, 0.4 ± 8.7 in.´lbf)
RlAxle bearing backlash Maximum0.05 mm (0.0020 in.)Rear axleAxle hub deviationMaximum0.07 mm (0.0028 in.)
*1: Front measuring point
Measure the distance from the ground to the head center of the front side lower suspension arm mounting
bolt.
*2: Rear measuring point
Measure the distance from the ground to the center of the rear axle beam mounting bolt.

SS0LM±06
SS±28
± SERVICE SPECIFICATIONSBRAKE
150 Author: Date:
2001 PRIUS (RM778U)
BRAKE
SERVICE DATA
BRAKE PEDAL
Brake pedal height from asphalt sheet127 ± 137 mm (5.08 ± 5.48 in.)
Brake pedal freeplay1 ± 6 mm (0.04 ± 0.24 in.)
Brake pedal reserve distance at 200 N (20 kgf, 45 Ibf)More than 85 mm (3.35 in.)
PARKING BRAKE PEDAL
Parking brake pedal travel at 294N (30 Kgf, 66.1 Ibf)5 ± 8 clicks
FRONT BRAKE
Front brake pad thickness STD11.0 mm (0.433 in.)
Front brake pad thickness Minimum1.0 mm (0.039 in.)
Front brake disc thickness STD22.0 mm (0.984 in.)
Front brake disc thickness Minimum20.0 mm (0.906 in.)
Front brake disc runout Maximum0.05 mm (0.0020 in.)
REAR BRAKE
Drum brake shoe lining thickness STD4.0 mm (0.157 in.)
Drum brake shoe lining thickness Minimum1.0 mm (0.039 in.)
Rear brake drum inside diameter STD200.0 mm (7.874 in.)
Rear brake drum inside diameterMaximum201.0 mm (7.913 in.)
Rear brake drum to shoe clearance0.6 mm (0.024 in.)

EM2011
EM2538
A01452
Plastigage
A12943
A01453
EM±38
± ENGINE MECHANICALCYLINDER HEAD
2001 PRIUS (RM778U)
14. INSPECT CAM LOBES
Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake 42.310 ± 42.410 mm (1.62637 ± 1.66968 in.)
Exhaust 44.046 ± 44.146 mm (1.73409 ± 1.73803 in.)
Minimum cam lobe height:
Intake 42.16 mm (1.6598 in.)
Exhaust 43.90 mm (1.7283 in.)
If the cam lobe height is less than minimum, replace the cam-
shaft.
15. INSPECT CAMSHAFT JOURNALS
Using a micrometer, measure the journal diameter.
No.1 journal diameter:
34.449 ± 34.465 mm (1.35626 ± 1.35689 in.)
Others journal diameter:
22.949 ± 22.965 mm (0.90350 ± 0.90413 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
16. INSPECT CAMSHAFT JOURNAL CLEARANCE
(a) Clean the bearing caps and camshaft journals.
(b) Place the camshafts on the cylinder head.
(c) Lay a strip of Plastigage across each of the camshaft jour-
nal.
(d) Install the bearing caps (See page EM±45).
Torque:
No.1 23 N´m (235 kgf´cm, 17 ft´lbf)
No.2 12.7 N´m (130 kgf´cm, 10 ft´lbf)
NOTICE:
Do not turn the camshaft.
(e) Remove the bearing caps.
(f) Measure the plastigage at its widest point.
Standard oil clearance:
0.040 ± 0.095 mm (0.00157 ± 0.00374 in.)
Maximum oil clearance:
0.115 mm (0.00453 in.)
If the oil clearance is greater than maximum, replace the cam-
shaft. If necessary, replace the bearing caps and cylinder head
as a set.
(g) Completely remove the Plastigage.
(h) Remove the camshafts.