2001 TOYOTA PRIUS Service Repair Manual

A13935
A13932
A11226
A13933
EM±30
± ENGINE MECHANICALCYLINDER HEAD
2001 PRIUS (RM778U)
12. REMOVE INTAKE MANIFOLD
Remove the 3 bolts, 2 nuts intake manifold and gasket.
13. DISCONNECT FRONT EXHAUST PIPE FROM EX-
HAUST MANIFOLD
(a) Remove the 2 bolts and 2 springs holding the front ex-
haust pipe to the exhaust manifold.
(b) Remove the gasket.
14. REMOVE EXHAUST MANIFOLD STAY
Remove the 3 bolts and exhaust manifold stay.
15. REMOVE EXHAUST MANIFOLD
(a) Remove the 4 bolts and upper heat insulator.
(b) Remove the 3 bolts 2 nuts, exhaust manifold and gasket.
16. REMOVE CAMSHAFT POSITION SENSOR
17. REMOVE ECT SENSOR
18. REMOVE OIL CONTROL VALVE
19. REMOVE PCV VALVE
20. REMOVE OIL FILLER CAP
21. REMOVE HEAD COVER (See page EM±15)
22. REMOVE INJECTOR (See page SF±11)
23. REMOVE TIMING CHAIN COVER (See page EM±15)
24. REMOVE CAMSHAFT TIMING SPROCKET AND
VALVE TIMING CONTROL ASSEMBLY
Hold the hexagonal head portion of the camshaft with a wrench,
and remove the 2 bolts and timing sprocket and valve timing
controller assembly.
NOTICE:

Be careful not to damage the cylinder head and valve
lifter with the wrench.

A12943
1
2973
4
3
368
5
A11228
1
23
45
67
8
9
10
A12944
± ENGINE MECHANICALCYLINDER HEAD
EM±31
2001 PRIUS (RM778U)

Do not disassembly the valve timing controller as-
sembly.
25. REMOVE CAMSHAFTS
Uniformly loosen and remove the 19 bearing cap bolts, in sever-
al passes, in the sequence shown, and remove the 9 bearing
caps, intake and exhaust camshafts.
26. REMOVE CYLINDER HEAD
(a) Disconnect the upper radiator hose from the water hose
union
(b) Disconnect the heater water hose from the water hose
union
(c) Using a 8 mm bi±hexagon wrench, uniformly loosen and
remove the 10 cylinder head bolts, in several passes, in
the sequence shown. Remove the 10 cylinder head bolts
and plate washers.
NOTICE:
Head warpage or cracking could result from removing
bolts in an incorrect order.
(d) Remove the bolt holding the water bypass pipe to the cyl-
inder head.
(e) Lift the cylinder head from the dowels on the cylinder
block and replace the cylinder head on wooden blocks on
a bench.
HINT:
If the cylinder head is difficult to lift off, pry between the cylinder
head and cylinder block with a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.

A01076
EM16K±03
A01077
A01068
A01069
A01070
± ENGINE MECHANICALCYLINDER HEAD
EM±33
2001 PRIUS (RM778U)
INSPECTION
1. CLEAN TOP SURFACES OF PISTONS AND CYL-
INDER BLOCK
(a) Turn the crankshaft, and bring each piston to top dead
center (TDC). Using a gasket scraper, remove all the car-
bon from the piston surface.
(b) Using a gasket scraper, remove all the gasket material
from the cylinder block surface.
(c) Using compressed air, blow carbon and oil from the bolt
holes.
CAUTION:
Protect your eyes when using high pressure compressed
air.
2. REMOVE GASKET MATERIAL
Using a gasket scraper, remove all the gasket material from the
cylinder block contact surface.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
3. CLEAN COMBUSTION CHAMBERS
Using a wire brush, remove all the carbon from the combustion
chambers.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
4. CLEAN CYLINDER HEAD
Using a soft brush and solvent, thoroughly clean the cylinder
head.

A01479
A01075
Cylinder Block Side
Intake Manifold Side
Exhaust Manifold Side
A01071
EM0580
EM±34
± ENGINE MECHANICALCYLINDER HEAD
2001 PRIUS (RM778U)
5. CLEAN VALVE GUIDE BUSHINGS
Using a valve guide bushing brush and solvent, clean all the
guide bushings.
6. INSPECT FOR FLATNESS
Using a precision straight edge and feeler gauge, measure the
surface contacting the cylinder block and the manifolds for war-
page.
Maximum warpage:
Cylinder block side0.05 mm (0.0020 in.)
Intake Manifold side0.10 mm (0.0394 in.)
Exhaust manifold side0.10 mm (0.0394 in.)
If warpage is greater than maximum, replace the cylinder head.
7. INSPECT FOR CRACKS
Using a dye penetrant, check the combustion chamber, intake
ports, exhaust ports and cylinder block surface for cracks.
If cracked, replace the cylinder head.
8. CLEAN VALVES
(a) Using a gasket scraper, chip off any carbon from the valve
head.
(b) Using a wire brush, thoroughly clean the valve.