2001 TOYOTA PRIUS Service Repair Manual

A11260
Seal Width:
4 ± 5 mmFIPG
FIPG
A11261
Seal
Packing
Seal
Packing
Seal Width
4 ± 5 mm EM±22
± ENGINE MECHANICALTIMING CHAIN
2001 PRIUS (RM778U)
3. INSTALL TIMING CHAIN COVER AND WATER PUMP
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the timing
chain cover, cylinder head and cylinder block.

Using a razor blade and a gasket scraper, remove
all the old packing (FIPG) material from the gasket
surfaces and sealing grooves.

Thoroughly clean all components to remove all the
loose material.

Using a non±residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the timing chain cover as shown in
the illustration.
Seal packing:
Part No. 08826 ± 00100 or equivalent

Install a nozzle that has been cut to a 4 ± 5 mm (0.16
± 0.20 in.) opening.

FIPG shall be accumulated in the groove for FIPG
to a depth of 2.5 mm (0.10 in.) or more.
HINT:
Avoid applying an excessive amount to the surface.

Parts must be assembled within 3 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(c) Apply seal packing to 4 locations as shown in the illustra-
tion.
Seal packing:
Part No. 08826 ± 00080 or equivalent

Install a nozzle that has been cut to a 4 ± 5 mm (0.16
± 0.20 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.

Parts must be assembled within 3 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(d) Install 2 new O±rings to the cylinder block and oil pan No.
1.

A11274
A B
CE D
F
AG
G
EB
A
AA
A11258
A
B
± ENGINE MECHANICALTIMING CHAIN
EM±23
2001 PRIUS (RM778U)
(e) Install the timing chain cover, new O±ring and water pump
with the 16 bolts and 3 nuts. Uniformly tighten the bolts
and nut in several passes.
Torque:
Bolt A 11 N´m (113 kgf´cm, 8 ft´lbf)
Bolt B 24 N´m (245 kgf´cm, 18 ft´lbf)
Bolt C 11 N´m (113 kgf´cm, 8 ft´lbf)
Bolt D 24 N´m (245 kgf´cm, 18 ft´lbf)
Bolt E 11 N´m (113 kgf´cm, 8 ft´lbf)
Nut F 24 N´m (245 kgf´cm, 18 ft´lbf)
Nut G 11 N´m (113 kgf´cm, 8 ft´lbf)
NOTICE:

Pay attention not to wrap the chain and slipper over
the chain cover seal line.

After installing the chain cover, must install the
mounting bracket and water pump within 15 minutes.
HINT:
Each bolt length in indicated in the illustration.
A 20 mm (0.787 in.)
B 30 mm (1.181 in.)
C 35 mm (1.378 in.)
D 20 mm (0.787 in.)
E 35 mm (1.378 in.)
4. INSTALL RH ENGINE MOUNTING BRACKET
(a) Apply seal packing to threads of the mounting bolt.
Seal packing:
Part No. 08826 ± 00080 or equivalent
HINT:
Do not apply seal packing to 2 or 3 threads of the bolt end.
(b) Install the mounting bracket with the 4 bolts.
Torque: 55 N´m (561 kgf´cm, 41 ft´lbf)
5. INSTALL CRANKSHAFT POSITION SENSOR
Torque:
Bolt A 7.5 N´m (76 kgf´cm, 66 in.´lbf)
Bolt B 11 N´m (113 kgf´cm, 8 ft´lbf)
6. INSTALL OIL CONTROL VALVE (See page EM±45)
Torque: 7.5 N´m (76 kgf´cm, 66 in.´lbf)

A11262
SST
SST
B00301
Seal
Packing
A11222
1
23
4
5
6
7
8
9
10
11
B11761
A13928
EM±24
± ENGINE MECHANICALTIMING CHAIN
2001 PRIUS (RM778U)
7. INSTALL CRANKSHAFT PULLEY
(a) Clean the crankshaft pulley inside.
(b) Install the pin to the crankshaft.
(c) Align the hole in the crank pulley with the pin position and
install the crank pulley.
(d) Using SST, install the pulley bolt.
SST 09213±70010, 09330±00021
Torque: 128 N´m (1,300 kgf´cm, 94 ft´lbf)
8. INSTALL CYLINDER HEAD COVER
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to 2 locations as shown in the illustra-
tion.
Seal packing:
Part No. 08826 ± 00080 or equivalent
(c) Install the gasket to the cylinder head cover.
HINT:
Part must be assembled within 3 minutes of application.
Otherwise the material must be remove and reapplied.
(d) Install the cylinder head cover and cable bracket with the
7 bolts, 2 seal washers and 2 nuts.
Uniformly tighten the bolts and nuts, in the several
passes, in the sequence shown.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
(e) Connect the 2 PCV hoses to the cylinder head cover.
9. CONNECT ENGINE WIRE TO CYLINDER HEAD COV-
ER
10. INSTALL IGNITION COILS (See page IG±7)
11. REMOVE RH ENGINE MOUNTING INSULATOR
Install the RH engine mounting insulator with the 5 bolts and 2
nuts.
12. INSTALL VSV TO RH ENGINE MOUNTING INSULA-
TOR
13. INSTALL DRIVE BELT
14. INSTALL ENGINE COOLANT RESERVOIR TANK
15. INSTALL AIR INLET