2001 TOYOTA PRIUS Service Repair Manual

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.

A11271
A11272
A10452
A10453
A10454
± ENGINE MECHANICALCYLINDER BLOCK
EM±65
2001 PRIUS (RM778U)
14. REMOVE OIL PAN NO. 1
(a) Uniformly loosen and remove the 13 bolts, in several
passes, in the sequence shown.
(b) Using screwdriver remove the oil pan No. 1 by prying the
portions between the cylinder block and oil pan No. 1.
(c) Remove the 2 O±rings from the cylinder block.
15. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while mov-
ing the connecting rod back and forth.
Standard thrust clearance:
0.16 ± 0.36 mm (0.0063 ± 0.0142 in.)
Maximum thrust clearance:
0.36 mm (0.0142 in.)
If the thrust clearance is greater than maximum, replace the
connecting rod assembly(s). If necessary, replace the crank-
shaft.
16. REMOVE CONNECTING ROD CAPS AND CHECK OIL
CLEARANCE
(a) Check the matchmarks on the connecting rod and cap are
aligned to ensure correct reassembly.
(b) Remove the 2 connecting rod cap bolts.
(c) Using the 2 removed connecting rod cap bolts, remove
the connecting rod cap and lower bearing by wiggling the
connecting rod cap right and left.
HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d) Clean the crank pin and bearing.
(e) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings.
If necessary, replace the crankshaft.

A10455
Plastigage
A10456
A10457
A01198
Mark
1, 2 or 3
Mark
1, 2 or 3
EM±66
± ENGINE MECHANICALCYLINDER BLOCK
2001 PRIUS (RM778U)
(f) Lay a strip of Plastigage the crank pin.
(g) Install the connecting rod cap with the 2 bolts.
(See page EM±78)
Torque:
1ST 15 N´m (150 kgf´cm, 11 ft´lbf)
2ND Turn 90 °
NOTICE:
Do not turn the crankshaft.
(h) Remove the 2 bolts, connecting rod cap and lower bear-
ing. (See procedure (b) and (c) above)
(i) Measure the Plastigage at its widest point.
Standard oil clearance:
0.016 ± 0.040 mm (0.0006 ± 0.0016 in.)
Maximum oil clearance:
0.06 mm (0.0024 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, grind or replace the crankshaft.
HINT:
If replacing a bearing, replace it with one having the same num-
ber as marked on the connecting rod. There are 3 sizes of stan-
dard bearings, marked º1º, º2º and º3º accordingly.
Reference
Standard bearing center wall thickness
Markmm (in.)
º1º1.488 ± 1.492 (0.0586 ± 0.0587)
º2º1.492 ± 1.496 (0.0587 ± 0.0589)
º3º1.496 ± 1.500 (0.0589 ± 0.0591)
(j) Completely remove the plastigage.

A01166
A10458
A10459
A10460
± ENGINE MECHANICALCYLINDER BLOCK
EM±67
2001 PRIUS (RM778U)
17. REMOVE PISTON AND CONNECTING ROD
ASSEMBLIES
(a) Using a ridge reamer, remove all the carbon from the top
of the cylinder.
(b) Push the piston, connecting rod assembly and upper
bearing through the top of the cylinder block.
HINT:

Keep the bearings, connecting rod and cap together.

Arrange the piston and connecting rod assemblies in the
correct order.
18. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while mov-
ing the crankshaft back and forth.
Standard thrust clearance:
0.09 ± 0.19 mm (0.0035 ± 0.0075 in.)
Maximum thrust clearance:
0.3 mm (0.012 in.)
If the thrust clearance is greater than maximum, replace the
thrust washer as a set.
Thrust washer thickness:
2.430 ± 2.480 mm (0.09567 ± 0.09764 in.)
19. REMOVE BEARING CAPS AND CHECK OIL CLEAR-
ANCE
(a) Uniformly loosen and remove the 10 bearing cap bolts in
several passes in the sequence shown.
(b) Using the 2 removed bearing cap bolts, remove the bear-
ing cap and lower bearing by wiggling the bearing cap
right and left.
HINT:
Keep the lower bearing inserted with the bearing cap.
(c) Lift out the crankshaft.
HINT:
Keep the upper bearings and thrust washers together with the
cylinder block.
(d) Clean each main journal and bearing.