2001 TOYOTA PRIUS head bolt

SS0ZS±01
4
5
6
7
8
9
10
11
B06431
Bolt Type
Hexagon Head Bolt
Normal Recess Bolt Deep Recess BoltStud Bolt Weld BoltClass
4T
5T
6T
7T
8T
9T
10T
11 T
No Mark
w/ WasherNo MarkNo Mark
w/ Washer
± SERVICE SPECIFICATIONSSTANDARD BOLT
SS±1
123 Author: Date:
2001 PRIUS (RM778U)
STANDARD BOLT
HOW TO DETERMINE BOLT STRENGTH

SS0ZT±01
SS±2
± SERVICE SPECIFICATIONSSTANDARD BOLT
2001 PRIUS (RM778U)
SPECIFIED TORQUE FOR STANDARD BOLTS
Specified torque
ClassDiameter
mm
Pitch
mmHexagon head boltHexagon flange boltClassmmmmN´mkgf´cmft´lbfN´mkgf´cmft´lbf
4T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.55
12.5
26
47
74
11 555
130
260
480
760
1,15048 in.´lbf
9
19
35
55
836
14
29
53
84
±60
145
290
540
850
±52 in.´lbf
10
21
39
61
±
5T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.56.5
15.5
32
59
91
14065
160
330
600
930
1,40056 in.´lbf
12
24
43
67
1017.5
17.5
36
65
100
±75
175
360
670
1,050
±65 in.´lbf
13
26
48
76
±
6T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.58
19
39
71
11 0
17080
195
400
730
1,100
1,75069 in.´lbf
14
29
53
80
1279
21
44
80
125
±90
210
440
810
1,250
±78 in.´lbf
15
32
59
90
±
7T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.510.5
25
52
95
145
23011 0
260
530
970
1,500
2,3008
19
38
70
108
16612
28
58
105
165
±120
290
590
1,050
1,700
±9
21
43
76
123
±
8T
8
10
121.25
1.25
1.2529
61
11 0300
620
1,10022
45
8033
68
120330
690
1,25024
50
90
9T
8
10
121.25
1.25
1.2534
70
125340
710
1,30025
51
9437
78
140380
790
1,45027
57
105
10T
8
10
121.25
1.25
1.2538
78
140390
800
1,45028
58
10542
88
155430
890
1,60031
64
11 6
11 T
8
10
121.25
1.25
1.2542
87
155430
890
1,60031
64
11 647
97
175480
990
1,80035
72
130

SS±8
± SERVICE SPECIFICATIONSENGINE MECHANICAL
130 Author: Date:
2001 PRIUS (RM778U) Cylinder
block
Cylinder head surface warpage Maximum
Cylinder bore diameter STD
Maximum
Main journal bore diameter Mark 0
Mark 1
mark 2
Mark 3
Mark 4
Mark 5
Mark 6
12 pointed head bearing cap sub±assembly bolt diameter
at tension portion STD
Minimum0.05 mm (0.0020 in.)
75.000 ± 75.013 mm (2.95275 ± 2.95326 in.)
75.013 mm (2.95326 in.)
50.000 ± 50.003 mm (1.96850 ± 1.96862 in.)
50.003 ± 50.005 mm (1.96862 ± 1.96870 in.)
50.005 ± 50.007 mm (1.96870 ± 1.96878 in.)
50.007 ± 50.010 mm (1.96878 ± 1.96889 in.)
50.010 ± 50.012 mm (1.96889 ± 1.96897 in.)
50.012 ± 50.014 mm (1.96897 ± 1.96905 in.)
50.014 ± 50.016 mm (1.96905 ± 1.96913 in.)
7.3 ± 7.5 mm (0.287 ± 0.295 in.)
7.3 mm (0.287 in.)
Piston and
Piston ring
Piston diameter
at 27 mm (1.063 in.) from the piston head
Piston oil clearance STD
Maximum
Piston ring groove clearance
Piston ring end gap
STD No. 1
No. 2
Oil
Maximum No. 1
No. 2
Oil
74.945 ± 74.955 mm (2.95058 ± 2.95098 in.)
0.045 ± 0.068 mm (0.00177 ± 0.00268 in.)
0.08 mm (0.0031 in.)
0.030 ± 0.070 mm (0.0012 ± 0.0028 in.)
0.22 ± 0.32 mm (0.0087 ± 0.0126 in.)
0.32 ± 0.47 mm (0.0126 ± 0.0185 in.)
0.15 ± 0.45 mm (0.0059 ± 0.0177 in.)
0.88 mm (0.0346 in.)
1.03 mm (0.0406 in.)
0.92 mm (0.0362 in.)
Connecting
rod
Thrust clearance STD
Maximum
Connecting rod thickness
Connecting rod bearing center wall thickness
Reference Mark 1
Mark 2
Mark 3
Connecting rod oil clearance STD
Maximum
Rod out±of±alignment Maximum per 100 mm (3.94 in.)
Rod twist Maximum per 100 mm (3.94 in.)
Bushing inside diameter
Piston pin diameter
Bushing oil clearance STD
Maximum
Connecting rod bolt diameter
at tension portion STD
Minimum0.16 ± 0.36 mm (0.0063 ± 0.0142 in.)
0.36 mm (0.0142 in.)
19.788 ± 19.840 mm (0.779 ± 0.781 in.)
1.488 ± 1.492 mm (0.0586 ± 0.0587 in.)
1.492 ± 1.496 mm (0.0587 ± 0.0589 in.)
1.496 ± 1.500 mm (0.0589 ± 0.0591 in.)
0.016 ± 0.040 mm (0.0006 ± 0.0016 in.)
0.06 mm (0.0024 in.)
0.05 mm (0.0020 in.)
0.05 mm (0.0020 in.)
18.010 ± 18.019 mm (0.7091 ± 0.7094 in.)
17.988 ± 18.007 mm (0.7086 ± 0.7089 in.)
0.009 ± 0.015 mm (0.0003 ± 0.0006 in.)
0.05 mm (0.0020 in.)
6.6 ± 6.7 mm (0.260 ± 0.264 in.)
6.4 mm (0.252 in.)

SS175±03
SS±10
± SERVICE SPECIFICATIONSENGINE MECHANICAL
2001 PRIUS (RM778U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Plug x Timing chain cover1515011
Chain vibration damper x Cylinder block9.09280 in .´lbf
Chain tensioner9.09280 in .´lbf
Timing chain cover Bolt A
Bolt B
Bolt C
Bolt D
Bolt E
Nut F
Nut G11
24
11
24
11
24
1111 2
245
11 2
245
11 2
245
11 28
18
8
18
8
18
8
RH engine mounting bracket x Timing chain cover5556141
Crankshaft position sensor x Timing chain cover Bolt A
Bolt B7.5
1176
11 266 in .´lbf
8
Oil control valve8.08271 in .´lbf
Crankshaft pulley x Crankshaft1281,30094
Cylinder head cover x Cylinder101007
RH engine mounting insulator Bolt A
Bolt B
Nut45
52
52459
530
53033
38
38
Cylinder head x Cylinder block 1st
2nd
3rd29.4
Turn 90°
Turn 90°300
Turn 90°
Turn 90°22
Turn 90°
Turn 90°
Water bypass pipe x Cylinder head9.09280 in .´lbf
No. 1 camshaft bearing cap x Cylinder head2323517
No. 2 camshaft bearing cap x Cylinder head12.713010
Camshaft timing sprocket x Camshaft6465047
Valve timing controller assembly x Camshaft6465047
Intake manifold x Cylinder head2020415
Exhaust manifold x Cylinder head2727520
Upper heat insulator x Exhaust manifold8.08271 in .´lbf
Exhaust manifold stay x Cylinder block2727520
Front exhaust pipe x Tailpipe Bolt A
Bolt B62
32630
33046
24
Connecting rod cap x Connecting rod 1st
2nd15
Turn 90°150
Turn 90°11
Turn 90°
Bearing cap x Cylinder block 1st
2nd22
Turn 90°220
Turn 90°16
Turn 90°
Oil pan No. 1 x Cylinder block2424518
Oil strainer x Oil pan No. 11111 28
Oil pan No. 2 x Oil pan No. 19.09280 in.´lbf
Oil filter union x Oil pan No. 13030621
Engine coolant drain plug x Cylinder block12.71309
Knock sensor x Cylinder block4445033
Water bypass pipe x Cylinder block9.09080 in.´lbf
Flywheel x Crankshaft8485762
Damper spring x Flywheel1616312

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.

SS1HM±01
± SERVICE SPECIFICATIONSBODY
SS±35
157 Author: Date:
2001 PRIUS (RM778U)
BODY
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
FRONT BUMPER±±±
Side marker x Bumper1.71715 in.´lbf
HOOD±±±
Hood x Hinge131309
Hood lock x Body8.38574 in.´lbf
FRONT DOOR±±±
Outside view mirror x Door7.88069 in.´lbf
Window regulator arm x Door4.95043 in.´lbf
Window regulator body x Door8.38574 in.´lbf
Door lock x Door Bolt:4.95043 in.´lbf
Door lock x Door Screw:4.95043 in.´lbf
Outside handle x Door5.45548 in.´lbf
Hinge x Body4344032 in.´lbf
Hinge x Door4344032 in.´lbf
Door lock striker x Body2323017 in.´lbf
REAR DOOR±±±
Window regulator x Door5.45548 in.´lbf
Door lock x Door4.95043 in.´lbf
Outside handle x Body5.45548 in.´lbf
Hinge x Body2526019
Hinge x Door3031022
Door lock striker x Body2323017
LUGGAGE COMPARTMENT DOOR AND HINGE±±±
Door lock x Door5.45548 in.´lbf
Hinge x Door8.38574 in.´lbf
Door lock striker x Body5.45548 in.´lbf
FRONT WIPER AND WASHER±±±
Wiper arm x Wiper link2627020
Wiper motor x Wiper link Bolt:5.45548 in.´lbf
Wiper motor x Wiper link Nut:1717513
Wiper link x Outer front cowl top panel7.47565 in.´lbf
Outer front cowl top panel x Body5.45548 in.´lbf
ROOF HEADLINING±±±
Inner rear view mirror x Body2.93026 in.´lbf
INSTRUMENT PANEL±±±
Front passenger airbag assembly x Reinforcement2020415
FRONT SEAT±±±
Seat cushion frame x Body3738027
Seatback assembly x Seat cushion frame4344032
REAR SEAT±±±
Seatback assembly x Body7.98170 in.´lbf

A13927
A13928
B11761
A11222
A11244
EM±16
± ENGINE MECHANICALTIMING CHAIN
2001 PRIUS (RM778U)
12. REMOVE RH ENGINE MOUNTING INSULATOR
(a) Set the jack to the engine.
HINT:
Place the wooden block between the jack and engine.
(b) Remove the 5 bolts, 2 nuts and RH engine mounting insu-
lator.
13. DISCONNECT ENGINE WIRE FROM CYLINDER HEAD
COVER
Remove the 3 bolts and disconnect the engine wire from the cyl-
inder head.
14. REMOVE CYLINDER HEAD COVER
(a) Remove the ignition coils (See page IG±6)
(b) Remove the 2 PCV hoses from the cylinder head cover.
(c) Remove the 7 bolts, 2 seal washers, 2 nuts, cylinder head
cover and gasket.
15. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with timing
mark º0º of the timing chain cover.

A11245
Timing Marks
A11253
SST
SST
A11254
SST
A11258
A11255
± ENGINE MECHANICALTIMING CHAIN
EM±17
2001 PRIUS (RM778U)
(b) Check that both timing marks on the camshaft timing
sprocket and valve timing controller assembly are facing
right up as shown in the illustration.
If not, turn the crankshaft 1 revolution (360°) and align the
marks as above.
16. REMOVE CRANKSHAFT PULLEY
(a) Using SST, remove the pulley bolt.
SST 09213±70010, 09330±00021
(b) Remove the crankshaft pulley and pin.
HINT:
If necessary, remove the pulley with SST.
SST 09950±50012 (09951±05010, 09952±05010,
09953±05020, 09954±05020)
17. REMOVE CRANKSHAFT POSITION SENSOR
(See page IG±12)
18. REMOVE RH ENGINE MOUNTING BRACKET
Remove the 4 bolts and mounting bracket.
19. REMOVE WATER PUMP (See page CO±6)
20. REMOVE OIL CONTROL VALVE (See page EM±29)
21. REMOVE TIMING CHAIN COVER
(a) Remove the 13 bolts and nut.
(b) Using a torx wrench socket (E8), remove the stud bolt.
(c) Remove the timing chain cover by prying the portions be-
tween the cylinder head and cylinder block with a screw-
driver.
NOTICE:
Be careful not to damage the contact surfaces of the timing
chain cover, cylinder head and cylinder block.