2001 TOYOTA PRIUS Service Repair Manual

A01455
A13949
P16860
± ENGINE MECHANICALCYLINDER HEAD
EM±39
2001 PRIUS (RM778U)
17. INSPECT CAMSHAFT THRUST CLEARANCE
(a) Install the camshafts (See page EM±45).
(b) Using a dial indicator, measure the thrust clearance while
moving the camshaft back and forth.
Standard thrust clearance:
0.040 ± 0.095 mm (0.0016 ± 0.0037 in.)
Maximum thrust clearance:
0.11 mm (0.0043 in.)
If the thrust clearance is greater than maximum, replace the
camshaft. If necessary, replace the bearing caps and cylinder
head as a set.
(c) Remove the camshafts.
18. INSPECT VALVE LIFTERS AND LIFTER BORES
(a) Using a caliper gauge, measure the lifter bore diameter
of the cylinder head.
Lifter bore diameter:
31.009 ± 31.025 mm (1.22082 ± 1.22145 in.)
(b) Using a micrometer, measure the lifter diameter.
Lifter diameter:
30.966 ± 30.976 mm (1.21913 ± 1.21953 in.)
(c) Subtract the lifter diameter measurement from the lifter
bore diameter measurement.
Standard oil clearance:
0.031 ± 0.059 mm (0.00122 ± 0.00232 in.)
Maximum oil clearance:
0.1 mm (0.004 in.)
If the oil clearance is greater than maximum, replace the lifter.
If necessary, replace the cylinder head.

A13936
A13937
EM±40
± ENGINE MECHANICALCYLINDER HEAD
2001 PRIUS (RM778U)
19. INSPECT INTAKE MANIFOLD
Using a precision straight edge and feeler gauge, measure the
surface contacting the cylinder head for warpage.
Maximum warpage: 0.10 mm (0.0039 in.)
If warpage is greater than maximum, replace the manifold.
20. INSPECT EXHAUST MANIFOLD
Using a precision straight edge and feeler gauge, measure the
surface contacting the cylinder head for warpage.
Maximum warpage: 0.70 mm (0.0276 in.)
If warpage is greater than maximum, replace the manifold.

A01067
80 ± 100°C
EM16L±02
A01066
SST
A13949
Both intake and exhaust
Bushing bore diameter
mm (in.)Bushing size
9.685 ± 9.706
(0.38130 ± 0.38213)Use STD
9.735 ± 9.756
(0.38327 ± 0.38493)Use O/S 0.05
A01446
SST
± ENGINE MECHANICALCYLINDER HEAD
EM±41
2001 PRIUS (RM778U)
REPLACEMENT
REPLACE VALVE GUIDE BUSHINGS
(a) Gradually heat the cylinder head to 80 ± 100°C (176 ±
212°F).
(b) Using SST and a hammer, tap out the guide bushing.
SST 09201±01055, 09950±70010 (09951±07100)
(c) Using a caliper gauge, measure the bushing bore diame-
ter of the cylinder head.
(d) Select the new guide bushing (STD or O/S 0.05).
If the bushing bore diameter of the cylinder head is greater than
9.706 mm (0.38213 in.), machine the bushing bore to the fol-
lowing dimension:
9.735 ± 9.756 mm (0.38327 ± 0.38493 in.)
If the bushing bore diameter of the cylinder head is greater than
9.756 mm (0.38493 in.), replace the cylinder head.
(e) Gradually heat the cylinder head to 80 ± 100°C (176 ±
212°F).
(f) Using SST and a hammer, tap in a new guide bushing to
the specified protrusion height.
SST 09201±01055, 09950±70010 (09951±07100)
Protrusion height:
9.0 ± 9.4 mm (0.354 ± 0.370 in.)

A01447
EM±42
± ENGINE MECHANICALCYLINDER HEAD
2001 PRIUS (RM778U)
(g) Using a sharp 5 mm reamer, ream the guide bushing to
obtain the standard specified clearance (See page
EM±33) between the guide bushing and valve stem.

EM16M±02
A11230
For Radiator Hose
For Water Bypass Hose 15 mm18 mm
A11231
Adhesive
A11232
AB
A01063
SST
± ENGINE MECHANICALCYLINDER HEAD
EM±43
2001 PRIUS (RM778U)
REASSEMBLY
HINT:

Thoroughly clean all parts to be assembled.

Before installing the parts, apply fresh engine oil to all slid-
ing and rotating surfaces.

Replace oil seals with new ones.
1. INSTALL WATER HOSE UNIONS
HINT:
When using a new cylinder head, water hose unions must be
installed.
(a) Mark the standard position away from the edge, onto the
water hose union.
(b) Apply adhesive to the water hose union hole of the cylin-
der head.
Adhesive:
Part No.08833±00070, THREE BOND 1324 or
equivalent
(c) Using a press, press in a new water hose union until there
is protruding from the cylinder head.
Standard protrusion:
A 29 mm (1.14 in.)
B 44 mm (1.73 in.)
NOTICE:
Avoid pressing a new water hose union in too far by mea-
suring the amount of protrusion while pressing.
2. INSTALL VALVES
(a) Using SST, push in a new oil seal.
SST 09201±41020

S05923
Intake Exhaust
Mark
ºNOKº
Gray Surface
Light Brown Surface
A01065
(1)
(2)(3)
(4)
A01061
SST
A07307
EM±44
± ENGINE MECHANICALCYLINDER HEAD
2001 PRIUS (RM778U)
HINT:
The intake valve oil seal is light brown and the exhaust valve oil
seal is gray.
NOTICE:
Pay much attention assembling the oil seal for intake and
exhaust. Assembling the wrong one may cause a failure.
(b) Install the valve (1), spring (2), valve spring (3), and spring
retainer (4).
(c) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202±70020 (09202±00010)
(d) Using a plastic±faced hammer and the valve stem (not in
use) tip wound with vinyl tape, lightly tap the valve stem
tip to ensure a proper fit.
NOTICE:
Be careful not to damage the valve stem tip.
3. INSTALL VALVE LIFTERS
(a) Install the valve lifter.
(b) Check that the valve lifter rotates smoothly by hand.