2001 TOYOTA PRIUS length

SS174±03
SS±6
± SERVICE SPECIFICATIONSENGINE MECHANICAL
128 Author: Date:
2001 PRIUS (RM778U)
ENGINE MECHANICAL
SERVICE DATA
Compression
pressureat 250 rpm STD
Minimum
Difference between each cylinder728 kPa (7.4 kgf/cm2, 106 psi)
534 kPa (5.4 kgf/cm2, 77 psi)
98 kPa (1.0 kgf/cm2, 14 psi)
Valve
clearance
at cold Intake
Exhaust
Valve lifter for repair part No. 06
No. 08
No. 10
No. 12
No. 14
No. 16
No. 18
No. 20
No. 22
No. 24
No. 26
No. 28
No. 30
No. 32
No. 34
No. 36
No. 38
No. 40
No. 42
No. 44
No. 46
No. 48
No. 50
No. 52
No. 54
No, 56
No. 58
No. 60
No. 62
No. 64
No. 66
No. 68
No. 70
No. 72
No. 740.17 ± 0.23 mm (0.007 ± 0.009 in.)
0.27 ± 0.33 mm (0.011 ± 0.013 in.)
5.060 mm (0.1992 in.)
5.080 mm (0.2000 in.)
5.100 mm (0.2008 in.)
5.120 mm (0.2016 in.)
5.140 mm (0.2024 in.)
5.160 mm (0.2031 in.)
5.180 mm (0.2039 in.)
5.200 mm (0.2047 in.)
5.220 mm (0.2055 in.)
5.240 mm (0.2063 in.)
5.260 mm (0.2071 in.)
5.280 mm (0.2079 in.)
5.300 mm (0.2087 in.)
5.320 mm (0.2094 in.)
5.340 mm (0.2102 in.)
5.360 mm (0.2110 in.)
5.380 mm (0.2118 in.)
5.400 mm (0.2126 in.)
5.420 mm (0.2134 in.)
5.440 mm (0.2142 in.)
5.460 mm (0.2150 in.)
5.480 mm (0.2157 in.)
5.500 mm (0.2165 in.)
5.520 mm (0.2173 in.)
5.540 mm (0.2181 in.)
5.560 mm (0.2189 in.)
5.580 mm (0.2197 in.)
5.600 mm (0.2205 in.)
5.620 mm (0.2213 in.)
5.640 mm (0.2220 in.)
5.660 mm (0.2228 in.)
5.680 mm (0.2236 in.)
5.700 mm (0.2244 in.)
5.720 mm (0.2252 in.)
5.740 mm (0.2260 in.)
Ignition timing7 ± 15° BTDC @ idle
Idle speedw/ Cooling fan off1,000 ± 50 rpm (A/C OFF)
1,200 ± 50 rpm (A/C ON)
Chain and
timing sprocketChain length at 16 linksMaximum
Camshaft timing sprocket wear (w/ chain) Minimum
Crankshaft timing sprocket wear (w/ chain) Minimum123.2 mm (4.850 in.)
96.2 mm (3.787 in.)
50.5 mm (1.988 in.)
Chain
tensioner
slipper and
vibration
damperWear Maximum1.0 mm (0.039 in.)

± 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.

A02397
OCV Signal Waveform
1 m sec./Division5 V/
Division
GND
(A) (A) (A)
DI±122
± DIAGNOSTICSENGINE
2001 PRIUS (RM778U)
2 Check operation of OCV.
PREPARATION:
(a) Start the engine and warmed it up.
(b) Connect the TOYOTA hand±held tester and select VVT from ACTIVE TEST menu.
CHECK:
Check the engine speed when operate the OCV by the TOYOTA hand±held tester.
OK:
VVT system OFF to ON (OCV OFF to ON):
Engine speed increases.
VVT system ON to OFF (OCV ON to OFF):
Engine is stalled.
HINT:
The change of engine speed lasts only few seconds.
OK VVT system is OK.*
*: DTC P1349 is also output after the foreign object is caught
in some part of the system in the engine oil and the system re-
turns to normal in a short time. As ECM controls so that foreign
objects are ejected, there is no problem about VVT. There is
also no problem since the oil filter should get the foreign object
in the engine oil.
NG
3 Check voltage between terminals OCV+ and OCV± of ECM connector.
Reference: INSPECTION USING OSCILLOSCOPE
Turn the ignition switch ON, check waveform between terminals
OCV+ and OCV± of the ECM connector.
HINT:

The correct waveform is as shown.

The waveform frequency (A) is lengthened as the engine
speed becomes higher.
NG Check and replace ECM (See page IN±41).
OK

A02397
OCV Signal Waveform
1 m sec./Division5 V/
Division
GND
(A) (A) (A)
± DIAGNOSTICSENGINE
DI±125
2001 PRIUS (RM778U)
3 Check voltage between terminals OCV+ and OCV± of ECM connector.
Reference: INSPECTION USING OSCILLOSCOPE
Turn the ignition switch ON, check waveform between terminals
OCV+ and OCV± of the ECM connector.
HINT:

The correct waveform is as shown.

The waveform frequency (A) is lengthened as the engine
speed becomes higher.
OK VVT system is OK.*
*: DTC P1349 is also output after the foreign object is caught
in some part of the system in the engine oil and the system re-
turns to normal in a short time. As ECM controls so that foreign
objects are ejected, there is no problem about VVT. There is
also no problem since the oil filter should get the foreign object
in the engine oil.
NG
Check and replace ECM (See page IN±41).
4 Check VVT controller assembly (See page EM±33).
NG Replace VVT controller assembly, and then go
to step 5.
OK
5 Check oil control valve (See page SF±35).
NG Replace oil control valve, and then go to step 6.
OK

± DIAGNOSTICSENGINE
DI±133
2001 PRIUS (RM778U)
DTC P1436 Bypass Valve Malfunction
CIRCUIT DESCRIPTION
Before the engine is started, the bypass valve remains open. When the engine is cold started, the ECM out-
puts a signal to the VSV (for HC adsorber and catalyst system), which open the passage between the intake
manifold and the actuator, thus applying a vacuum to the actuator. As a result, the bypass valve closes.
Immediately after the engine has started, the exhaust gases pass through the adsorber material in with HC
becomes adsorbed and stored for a certain length of time (until the temperature of the front TWC rises).
Thus, the release of HC into the atmosphere is prevented when the temperature of the TWC is low.
After the TWC has warmed up, the VSV closes the passage between the intake manifold and the actuator,
causing the bypass valve to open. Then, as the temperature of the rear TWC rises, the temperature of the
adsorber material that surrounds it also rises, and the HC starts to desorb, and becomes cleaned by the
TWC.
Furthermore, this system activates the VSV when decelerating and the HC adsorber has become the speci-
fied temperature, allowing the vacuum from the intake manifold to close the bypass valve in order to scav-
enge the HC that remains in the adsorber material.
DTC No.DTC Detecting ConditionTrouble Area
P1436
With cold start when the water temperature and intake air
temperature were ±10 °C (14 °F)to 40 °C (104 °F), and
when the water temperature has reached 45 °C (113 °F) or
more and the engine load factor has become more than 30
%, the valve operation is not preformed normally.

Vacuum line

Actuator

Front exhaust pipe
INSPECTION PROCEDURE
1 Check vacuum hose and tube between VSV and actuator for HC adsorber and
catalyst system.
CHECK:
Check that the vacuum hose and tube for clog and deformation.
NG Repair or replace.
OK
2 Check actuator operation (See page EC±13).
OK Recheck after assembly.
NG
DI7T0±01

± DIAGNOSTICSENGINE
DI±153
2001 PRIUS (RM778U)
DTC P3190 Poor Engine Power
DTC P3191 Engine dose not Start
CIRCUIT DESCRIPTION
From the HV ECU, the ECM receives data such as power output required for the engine (required output),
estimated torque produced by the engine (estimated torque), engine RPM of control target (target RPM),
whether the engine is in start mode or not. Then, based on the required output and target RPM, the ECM
calculates a target torque that is to be produced by the engine and compares it with the estimated torque.
If the estimated torque is very low compared with the target torque, or the engine start mode continues at
the engine RPM or for the duration calculated by water temperature, an abnormal condition is detected.
DTC No.DTC Detecting ConditionTrouble Area
P3190
Following condition (a) to (e) continues at a fixed engine RPM
or a fixed length of time:
(a) Communication with HV ECU is normal.
(b) Engine RPM is a fixed value or more.
(c) Engine star mode is not active.
(d) Target torque is a fixed value or more.
(e) Ratio of estimated torque against target torque is less than
20 %.

Air induction system

Throttle body

Fuel pressure

Engine

Air flow meter

Out of fuel
Wt t
P3191
Following condition (a) to (c) continues at a fixed engine RPM
or for a fixed length of time:
(a) Vommunication with HV ECU is normal.
(b) Engine RPM is a fixed value or more.
(c) Engine start mode is active.
Water temp. sensor

Crankshaft position sensor

Camshaft position sensor

ECM
WIRING DIAGRAM
Refer to DTC P1636 on page DI±146.
INSPECTION PROCEDURE
1 Are there any other codes begin output?
YES Go to relevant DTC chart.
NO
DI7T6±01

EJECT Error 45 62
(CD player)Magazine cannot be ejected.
Scratched/
Reversed Disc 46 62
(CD player)Scratches or dirt is found on CD sur-
face or CD is set upside down.Replace radio receiver assembly.
Inspect CD.
Physical address: 178 Navigation ECU
Gyro Error Error in gyro sensor is detected.
(Abnormal value in voltage output
from sensor is detected for more
than specified time.)
Check the Gyro voltage in the
diagnosis system mode. 10 58
(Navigation ECU)
Map Disc Error Data cannot be read for a specified
time due to scratches or dirt on disc
surface or insertion of music CD.
Inspect disc and replace if neces-
sary. (Visually check disc surface
and wipe it with soft cloth.) 42 58
(Navigation ECU)
Vehicle speed
sensor Signal
ErrorInput error of vehicle speed sensor
signal is detected. (When no vehicle
speed sensor signal has been input
for a specified time.)
Check the vehicle speed signal in
the diagnosis system mode.

Inspect wire harness for vehicle
speed signal.

If wire harness is normal, replace
navigation ECU. 43 58
(Navigation ECU)
Player Error Malfunction of player continues for a
specified length of time.
Check if disc can be inserted/tak-
en out or not. If not , replace naviga-
tion ECU.

When the same code is detected
in recheck after deleting the DTC
memory. 44 58
(Navigation ECU)
GPS Receiver
ErrorOperation error of GPS receiver is
detected.
At an outdoor site with a clear
view, operate to display the GPS in-
formation screen of the diagnosis
system. If GPS time stamp is not
properly displayed after 15 min. or
more, replace navigation ECU. 11 58
(GPS receiver)
GPS Antenna
ErrorOperation condition of GPS anten-
na cable is detected. (Open circuit,
connection failure of connectors,
etc.)
Check if the GPS antenna is cor-
rectly connected or positioned or
not. After replacing the antenna, if
the error remains, replace the navi-
gation ECU. 40 58
(GPS receiver)
Power Supply
Error of GPS
AntennaAbnormal voltage of GPS antenna
cable or short circuit is detected.
Inspect GPS antenna and replace
if necessary. (When no continuity is
identified between connector's core
and sealed part, GPS antenna is
normal.)

If GPS antenna is normal, replace
navigation ECU. 41 58
(GPS receiver)
Player Temp.
Too HighReadout cannot be done because
temperature around player's pickup
(reading part) is too high.With IG switch OFF, leave vehicle in
cool shaded place for a while and
recheck. After deleting the DTC
memory, If same code detected, re-
place navigation ECU. 45 58
(Navigation ECU)
*2: Even if no failure is detected, it may be stored depending on the battery condition or voltage for starting an engine.
*3: It is stored when 180 sec. has passed after the power supply connector is pulled out after engine start.
*4: It may be stored when the engine key is turned again 1 min. after engine start.
*5: It may be stored when the engine key is turned again after engine start.
*6: When 210 sec. has passed after pulling out the power supply connector of the master component with the ignition
switch in ACC or ON, this code is stored.
± DIAGNOSTICSNAVIGATION SYSTEM
DI±817
2001 PRIUS (RM778U)