2001 TOYOTA PRIUS engine coolant

EM17B±02
A11250
Water Bypass Pipe
Knock Sensor
Thermostat
Water Inlet Engine Coolant
Drain Union

N´m(kgf´cm, ft´lbf) : Specified torque
Non±reusable part

Precoated part
Gasket


GasketOil Pressure
Switch
9.0 (90, 80 in.´lbf)
9.0 (90, 80 in.´lbf)
9.0 (90. 80 in.´lbf)
9.0 (90, 80 in.´lbf)
EM±62
± ENGINE MECHANICALCYLINDER BLOCK
1178 Author: Date:
2001 PRIUS (RM778U)
CYLINDER BLOCK
COMPONENTS

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.

P12477
Adhesive
A10451
± ENGINE MECHANICALCYLINDER BLOCK
EM±83
2001 PRIUS (RM778U)
18. INSTALL ENGINE COOLANT DRAIN UNION
(a) Apply adhesive to 2 or 3 threads.
Adhesive:
Part No. 08833±00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Install the drain union.
Torque: 35 N´m (350 kgf´cm, 25 ft´lbf)
HINT:
After applying the specified torque, rotate the drain union clock-
wise until its drain port is facing downward.
19. INSTALL KNOCK SENSOR
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
20. INSTALL OIL PRESSURE SWITCH
(See page LU±1)
21. INSTALL THERMOSTAT
(See page CO±12)
22. INSTALL WATER BYPASS PIPE
Torque: 9.0 N´m (92 kgf´cm, 80 in.´lbf)
23. INSTALL ENGINE WIRE
24. INSTALL CYLINDER HEAD
(See page EM±45)
25. INSTALL TIMING SPROCKETS AND TIMING CHAIN
(See page EM±21)
26. REMOVE ENGINE STAND

CO04E±09
B11768
Engine
Drain Plug
Radiator
Drain Plug
CO±2
± COOLINGCOOLANT
2001 PRIUS (RM778U)
REPLACEMENT
1. DRAIN ENGINE COOLANT
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
(b) Loosen the radiator drain plug (on the right side of the ra-
diator lower tank) and engine drain plug on the engine
coolant drain union (on the right front of the cylinder
block), and drain the coolant.
(c) Close the drain plugs.
Torque: 12.7 N´m (130 kgf´cm, 9 ft´lbf) for engine
2. FILL ENGINE COOLANT
(a) Slowly fill the system with coolant.

Use of improper coolants may damage the engine
cooling system.

Use ºToyota Long Life Coolantº or equivalent and
mix it with plain water according to the manufacture
directions.

Use of the coolant which includes more than 50%
[freezing protection down to ±35°C (±31°F)] or 60%
[freezing protection down to ±50°C (±58°F)] of eth-
ylene±glycol is recommended, but not more than
70%.
NOTICE:

Do not use an alcohol type coolant or plain water
alone.

The coolant should be mixed with plain water (prefer-
ably demineralized water or distilled water).
Capacity: 4.9 litters (5.2 US qts, 4.3 lmp qts)
(b) Install the radiator cap and start the engine. After repeat-
edly idling and racing the engine several times for approx.
2 minutes, stop the engine.
(c) Remove the radiator cap and fill the radiator with engine
coolant until it reaches the rim of the radiator filler.
If the engine coolant level of the radiator drops when grasping
the radiator inlet hose and outlet hose several times by hand,
add more coolant.
(d) Install the radiator cap. Activate inspection mode (See
page IN±10). Warm it up until the radiator fan starts to turn
with the engine speed at less than 2,500 rpm.
NOTICE:
Stop the engine immediately after the radiator fan starts to
turn.
(e) Stop the engine and cool it down.
NOTICE:
Cool down the engine until its temperature becomes below
50°C (122 °F).

± COOLINGCOOLANT
CO±3
2001 PRIUS (RM778U)
(f) Remove the radiator cap and check the engine coolant
level of the radiator. If it has dropped, repeat steps (d) to
(g).
(g) Bleed air from water pump.
Set the vehicle in the following conditions:

Ignition switch ON

Blower speed control dial to LO

Temperature control dial to MAX. HOT
(h) Operate the water pump in the following conditions:

The engine stopped

The blower switch ON

Temperature control dial at MAX. HOT
HINT:
Operate the water pump until a sound of the air±containing en-
gine coolant can not be heard from the heater core.
(i) When the engine coolant remains full, fill the radiator res-
ervoir tank with engine coolant to the maximum level.
3. CHECK FOR COOLANT LEAKS
4. CHECK ENGINE COOLANT SPECIFIC GRAVITY IS
CORRECT

CO143±01
Z00570
Radiator Cap Tester
Radiator Cap
30° or More CO±14
± COOLINGRADIATOR AND CONDENSER MODULE
2001 PRIUS (RM778U)
ON±VEHICLE INSPECTION
1. REMOVE RADIATOR CAP
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
2. INSPECT RADIATOR CAP
NOTICE:

If the radiator cap has contaminations, always rinse
it with water.

Before using a radiator cap tester, wet the relief valve
and pressure valve with engine coolant or water.

When performing steps (a) and (b) below, keep the ra-
diator cap tester at an angle of over 30°above the hor-
izontal.
(a) Using a radiator cap tester, slowly pump the tester and
check that air is coming from the vacuum valve.
Pump speed: 1 push/(3 seconds or more)
NOTICE:
Push the pump at a constant speed.
If air is not coming from the vacuum valve, replace the radiator
cap.
(b) Pump the tester and measure the relief valve opening
pressure.
Pump speed: 1 push within 1 seconds
NOTICE:
This pump speed is for the first pump only (in order to close
the vacuum value). After this, the pump speed can be re-
duced.
Standard opening pressure:
74 ± 103 kPa (0.75 ± 1.05 kgf´cm
2, 10.7 ± 14.9 psi)
Minimum opening pressure:
79 kPa (0.8 kgf´cm
2, 11.5 psi)
HINT:
Use the tester's maximum reading as the opening pressure. If
the opening pressure is less than minimum, replace the radiator
cap.

B11773
Radiator Cap Tester
± COOLINGRADIATOR AND CONDENSER MODULE
CO±15
2001 PRIUS (RM778U)
3. INSPECT COOLING SYSTEM FOR LEAKS
(a) Fill the radiator with coolant and attach a radiator cap tes-
ter.
(b) Warm up the engine.
(c) Pump it to 118 kPa (1.2 kgf´cm
2, 17.1 psi), and check that
the pressure drops.
If the pressure drops, check the hoses, radiator or water pump
for leaks. If no external leaks are found, check the heater core,
cylinder block and head.
4. REINSTALL RADIATOR CAP

CO145±01
I17955
I17954
± COOLINGRADIATOR AND CONDENSER MODULE
CO±17
2001 PRIUS (RM778U)
REMOVAL
1. DISCHARGE REFRIGERANT FROM REFRIGERATION
SYSTEM
HINT:
At the time of installation, please refer to the following item.
Evacuate air from refrigeration system.
Charge system with refrigerant and inspect for leakage of refrig-
erant.
Specified amount: 500 ± 50 g (17.64 ± 1.76 oz.)
2. DRAIN ENGINE COOLANT FROM RADIATOR
HINT:
It is not necessary to drain out all the coolant.
3. REMOVE ELECTRIC COOLING FAN ASSEMBLY
(See Page CO±22)
4. REMOVE FRONT BUMPER (See Page BO±4)
5. REMOVE RADIATOR RESERVOIR HOSE
6. DISCONNECT DISCHARGE AND LIQUID TUBE
(a) Remove the 2 bolts and disconnect discharge and liquid
tube.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
NOTICE:
Cap open the fittings immediately to keep moisture or dirt
out of the system.
HINT:
At the time of installation, please refer to the following item.
Lubricate 2 new O±rings with compressor oil and install them
to the tubes.
(b) Remove the bolt.
(c) Disconnect the liquid tube and remove the bracket.
7. REMOVE RADIATOR UPPER SUPPORT
Remove the 2 bolts and 2 radiator upper supports.