Download
Share
Print this page
Toyota Prius 2010 Repair Manual
  1. Manuals
  2. Brands
  3. Toyota Manuals
  4. Automobile
  5. Prius 2010
  6. Repair manual

Toyota Prius 2010 Repair Manual

Hide thumbs Also See for Prius 2010:

Advertisement

Quick Links

Download this manual
ILLUSTRATION

Advertisement

loading
Need help?

Need help?

Do you have a question about the Prius 2010 and is the answer not in the manual?

Questions and answers

Related Manuals for Toyota Prius 2010

Summary of Contents for Toyota Prius 2010

  • Page 1 ILLUSTRATION...

  • Page 3: On-Vehicle Inspection

    ON-VEHICLE INSPECTION 1. INSPECT THROTTLE BODY ASSEMBLY (a) Check for throttle control motor operating sound. (1) Turn the power switch on (IG). (2) When depressing the accelerator pedal, check the operating sound of the motor. Make sure that no friction noises are emitted from the motor.
  • Page 4 REMOVAL 1. REMOVE NO. 1 ENGINE UNDER COVER 2. DRAIN ENGINE COOLANT (for Engine) 3. REMOVE NO. 2 CYLINDER HEAD COVER 4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (a) Disconnect the mass air flow meter connector. (b) Release the 2 clamps. (c) Loosen the hose clamp and remove the air cleaner cap.
  • Page 5 (b) Separate the wire harness clamp from the inlet air cleaner assembly. (c) Remove the 3 bolts and inlet air cleaner assembly. 6. REMOVE AIR CLEANER CASE (a) Remove the air cleaner filter element. (b) Separate the hose from the 3 hose clamps. (c) Remove the 3 bolts and air cleaner case.
  • Page 6 (b) Unlock the hose clamp and remove the air cleaner hose assembly. 8. REMOVE THROTTLE BODY ASSEMBLY (a) Disconnect the throttle body connector and the 2 water by-pass hoses. (b) Remove the 2 bolts, 2 nuts and throttle body assembly. (c) Remove the gasket from the intake manifold.
  • Page 7 INSPECTION 1. INSPECT THROTTLE BODY ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Text in Illustration Component without harness connected (Throttle Body) Standard Resistance: Tester Connection Condition Specified Condition 1 (M-) - 2 (M+) 20°C (68°F) 0.3 to 100 Ω...

  • Page 8: Installation

    INSTALLATION 1. INSTALL THROTTLE BODY ASSEMBLY (a) Install a new gasket onto the intake manifold. (b) Install the throttle body assembly with the 2 bolts and 2 nuts. Torque: 10 N·m (102 kgf·cm, 7ft·lbf) (c) Connect the 2 water by-pass hoses and throttle body connector. 2.
  • Page 9 (b) Install the hose to the 3 hose clamps. (c) Install the air cleaner filter element. 4. INSTALL INLET AIR CLEANER ASSEMBLY (a) Install the inlet air cleaner assembly with the 3 bolts. Torque: 7.0 N·m (71 kgf·cm, 62in·lbf) (b) Connect the wire harness clamp to the inlet air cleaner assembly. (c) Install the hose to the hose clamp.
  • Page 10 (b) Tighten the hose clamp. (c) Connect the mass air flow meter connector. 6. ADD ENGINE COOLANT (for Engine) 7. INSPECT FOR COOLANT LEAK (for Engine) 8. INSTALL NO. 2 CYLINDER HEAD COVER 9. INSTALL NO. 1 ENGINE UNDER COVER 10.
  • Page 11 Cable disconnected from negative (-) battery terminal Store Malfunction detected (2nd trip) condition No malfunctions in 40 driving cycles Current Clear DTCs cleared using Techstream condition Cable disconnected from negative (-) battery terminal Permanent Store Malfunction detected (2nd trip) Timothy Frank 2010 Toyota Prius...
  • Page 12 (misfire and fuel system DTCs) Malfunction detected (2nd trip) Power switch turned to on (IG) after normal judgment obtained in 3 consecutive driving cycles DTCs cleared using Techstream Cable disconnected from negative (-) battery terminal Timothy Frank 2010 Toyota Prius...
  • Page 13 (d) Enter the following menus: Powertrain / Engine and ECT / Trouble Codes. (e) Check the DTC(s) and freeze frame data, and then write them down. (f) Check the details of the DTC(s) 2. CLEAR DTC (Pending and Current DTC) Timothy Frank 2010 Toyota Prius...
  • Page 14 Even if the following procedure is not performed, permanent DTCs are cleared by obtaining a normal judgment during 3 consecutive driving cycles. (a) Connect the Techstream to the DLC3. (b) Turn the power switch on (IG). Timothy Frank 2010 Toyota Prius...
  • Page 15 4. Allow 10 minutes or more to elapse from the time the engine is started. (i) Enter the following menus: Powertrain / Engine and ECT / Trouble Codes. (j) Check that the permanent DTCs have been cleared. HINT: The permanent DTCs are cleared when the universal trip is completed. Timothy Frank 2010 Toyota Prius...
  • Page 16 17. REMOVE SPARK PLUG TUBE GASKET 18. SET NO. 1 CYLINDER TO TDC/COMPRESSION (a) Turn the crankshaft pulley until its notch and timing mark "0" of the timing chain cover are aligned. Text in Illustration Timing Mark Timothy Frank 2010 Toyota Prius...
  • Page 17 Do not turn the crankshaft without the No. 1 chain tensioner installed. 21. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY 22. REMOVE TIMING CHAIN COVER OIL SEAL 23. REMOVE CHAIN TENSIONER SLIPPER (a) Remove the chain tensioner slipper from the cylinder block. Timothy Frank 2010 Toyota Prius...
  • Page 18 (a) Remove the 2 bolts and No. 2 chain vibration damper. 26. REMOVE CHAIN SUB-ASSEMBLY (a) Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear counterclockwise to loosen the chain between the camshaft timing gears. Timothy Frank 2010 Toyota Prius...
  • Page 19 Be sure to cover the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released. (c) Prick a hole in the tape covering the oil hole as shown in the illustration. (Procedure A) Timothy Frank 2010 Toyota Prius...
  • Page 20 28. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY (a) Remove the flange bolt while holding the hexagonal portion of the camshaft with a wrench, and then remove the camshaft timing gear. Text in Illustration Flange Bolt Do not remove Timothy Frank 2010 Toyota Prius...
  • Page 21 (b) Uniformly loosen and remove the 15 bearing cap bolts in the sequence shown in the illustration. NOTICE: Uniformly loosen the bearing cap bolts while keeping the camshaft housing level. (c) Remove the 5 bearing caps. Timothy Frank 2010 Toyota Prius...
  • Page 22 32. REMOVE NO. 2 CAMSHAFT (a) Remove the No. 2 camshaft. 33. REMOVE NO. 1 CAMSHAFT BEARING (a) Remove the 2 No. 1 camshaft bearings. 34. REMOVE NO. 2 CAMSHAFT BEARING (a) Remove the 2 No. 2 camshaft bearings. Timothy Frank 2010 Toyota Prius...
  • Page 23 (b) Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver. Text in Illustration Protective Tape NOTICE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing. HINT: Tape the screwdriver tip before use. Timothy Frank 2010 Toyota Prius...

  • Page 24: Installation

    Text in Illustration Vernier Caliper Standard dimension (A): 1.05 to 1.75 mm (0.0413 to 0.0689 in.) NOTICE: Position the bearings to the center of the bearing cap by measuring dimension A. Timothy Frank 2010 Toyota Prius...
  • Page 25 (c) Install the No. 2 camshaft to the camshaft housing. 4. INSTALL CAMSHAFT (a) Clean the camshaft journals. (b) Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps. (c) Install the camshaft to the camshaft housing. Timothy Frank 2010 Toyota Prius...
  • Page 26 Valve Stem Cap Valve Rocker Arm Valve Lash Adjuster (b) Apply seal packing in a continuous line as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard Seal Diameter: Area Specified Condition Timothy Frank...
  • Page 27 After installing the camshaft housing, wipe off any seal packing that seeped out from between the housing and cylinder head. 7. INSTALL CAMSHAFT TIMING SPROCKET Timothy Frank 2010 Toyota Prius...
  • Page 28 Do not turn the camshaft timing gear in the retard direction (clockwise). (c) Check that there is no clearance between the camshaft timing gear and camshaft flange. Text in Illustration Camshaft Timing Gear Flange Clearance Timothy Frank 2010 Toyota Prius...
  • Page 29 9. INSTALL NO. 1 CHAIN VIBRATION DAMPER (a) Install the chain vibration damper with the 2 bolts. Torque: 21 N·m (214 kgf·cm, 15ft·lbf) 10. SET NO. 1 CYLINDER TO TDC/COMPRESSION (a) Temporarily install the crankshaft pulley bolt. Timothy Frank 2010 Toyota Prius...
  • Page 30 The mark plate on the camshaft side is colored orange. Do not pass the chain around the sprocket of the camshaft timing gear. Only place it on the sprocket. Pass the chain through the No. 1 vibration damper. Timothy Frank 2010 Toyota Prius...
  • Page 31 (d) Align the mark plate (yellow) and timing mark and install the chain to the crankshaft timing gear. Text in Illustration Mark Plate (Yellow) Timing Mark HINT: The mark plate on the crankshaft side is colored pink. Timothy Frank 2010 Toyota Prius...
  • Page 32 Text in Illustration Timing Mark Mark Plate (Orange) Mark Plate (Yellow) 13. INSTALL NO. 2 CHAIN VIBRATION DAMPER (a) Install the No. 2 chain vibration damper with the 2 bolts. Torque: 10 N·m (102 kgf·cm, 7ft·lbf) Timothy Frank 2010 Toyota Prius...
  • Page 33 Text in Illustration Hook Push Raise CORRECT INCORRECT NOTICE: Make sure that the cam engages the first tooth of the plunger to allow the Timothy Frank 2010 Toyota Prius...
  • Page 34 (d) Turn the crankshaft clockwise and check that the plunger is extended. Text in Illustration Plunger Turn Plunger Extended 19. INSTALL SPARK PLUG TUBE GASKET 20. INSTALL CYLINDER HEAD COVER GASKET 21. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Timothy Frank 2010 Toyota Prius...
  • Page 35 31. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 32. INSTALL THROTTLE BODY ASSEMBLY 33. INSTALL ENGINE HANGERS 34. REMOVE ENGINE ON ENGINE STAND 35. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (a) Install the engine assembly with transaxle Timothy Frank 2010 Toyota Prius...
  • Page 36 COMPONENTS ILLUSTRATION ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 37 2010 Toyota Prius Repair Manual...
  • Page 38 If the thrust clearance is greater than the maximum, replace the connecting rod assemblies as necessary. If necessary, replace the crankshaft. 3. INSPECT CONNECTING ROD OIL CLEARANCE (a) Check that the matchmarks on the connecting rod and cap are aligned 2010 Toyota Prius Repair Manual...
  • Page 39 If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. (f) Lay a strip of Plastigage on the crank pin. Text in Illustration Plastigage (g) Check that the front mark of the connecting rod cap is facing forward and install the connecting rod cap. 2010 Toyota Prius Repair Manual...
  • Page 40 (1) Using SST, install and alternately tighten the bolts of the connecting rod cap in several steps. SST: 09205-16011 Torque: 20 N·m (204 kgf·cm, 15ft·lbf) NOTICE: Do not turn the crankshaft. (k) Step 2: Text in Illustration Paint Mark Engine Front 2010 Toyota Prius Repair Manual...
  • Page 41 Standard Connecting Rod Large End Bore Diameter: Mark Specified Condition Mark 1 47.000 to 47.008 mm (1.85039 to 1.85070 in.) Mark 2 47.009 to 47.016 mm (1.85074 to 1.85102 in.) Mark 3 47.017 to 47.024 mm (1.85106 to 1.85133 in.) 2010 Toyota Prius Repair Manual...
  • Page 42 5. REMOVE CONNECTING ROD BEARING (a) Remove the connecting rod bearings. HINT: Arrange the removed parts in the correct order. 6. REMOVE PISTON RING SET (a) Using a piston ring expander, remove the 2 compression rings. 2010 Toyota Prius Repair Manual...
  • Page 43 The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. 8. INSPECT CRANKSHAFT THRUST CLEARANCE (a) Using a dial indicator, measure the thrust clearance while prying the 2010 Toyota Prius Repair Manual...
  • Page 44 (c) Lift out the crankshaft. (d) Check each crankshaft journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. 10. REMOVE UPPER CRANKSHAFT THRUST WASHER 2010 Toyota Prius Repair Manual...
  • Page 45 13. CLEAN CYLINDER BLOCK NOTICE: If the cylinder is washed at high temperatures, the cylinder liner will stick out beyond the cylinder block. Always wash the cylinder block at a temperature of 45°C (113°F) or less. 2010 Toyota Prius Repair Manual...
  • Page 46 14. REMOVE STUD BOLT NOTICE: If a stud bolt is deformed or its threads are damaged, replace it. 2010 Toyota Prius Repair Manual...
  • Page 47 If the warpage is more than the maximum, replace the cylinder block. 2. INSPECT CYLINDER BORE (a) Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in both the thrust and axial directions. 2010 Toyota Prius Repair Manual...
  • Page 48 If the average diameter of the 4 positions is more than the maximum, replace the cylinder block. 3. INSPECT PISTON (a) Using a gasket scraper, remove the carbon from the piston top. (b) Using a groove cleaning tool or broken ring, clean the piston ring grooves. 2010 Toyota Prius Repair Manual...
  • Page 49 No. 2 Compression Ring 0.02 to 0.055 mm (0.000787 to 0.00217 in.) Oil Ring 0.02 to 0.06 mm (0.000787 to 0.00236 in.) If the groove clearance is not as specified, replace the piston with pin. 2010 Toyota Prius Repair Manual...
  • Page 50 20.006 to 20.015 mm (0.78764 to 0.78799 in.) Item Specified Condition Mark A 20.006 to 20.009 mm (0.78764 to 0.78775 in.) Mark B 20.010 to 20.012 mm (0.78779 to 0.78787 in.) Mark C 20.013 to 20.015 mm (0.78791 to 0.78799 in.) 2010 Toyota Prius Repair Manual...
  • Page 51 (d) Subtract the piston pin diameter measurement from the piston pin bore diameter measurement. Text in Illustration *a Upper Side: *b Lower Side: *c Front Mark *d Piston Pin Bore Diameter Mark *e Connecting Rod Small Bore Diameter Mark 2010 Toyota Prius Repair Manual...
  • Page 52 If the oil clearance is more than the maximum, replace the connecting rod small end bush. If necessary, replace the piston with pin as a set. 8. INSPECT CONNECTING ROD SUB-ASSEMBLY (a) Using a connecting rod aligner and feeler gauge, check the connecting rod alignment. 2010 Toyota Prius Repair Manual...
  • Page 53 Maximum circle runout: 0.03 mm (0.00118 in.) If the circle runout is more than the maximum, replace the crankshaft. (b) Inspect the main journals. (1) Using a micrometer, measure the diameter of each main journal. 2010 Toyota Prius Repair Manual...
  • Page 54 (c) Inspect the crank pin. (1) Using a micrometer, measure the diameter of each crank pin. Standard diameter: 43.992 to 44.000 mm (1.7320 to 1.7323 in.) If the diameter is not as specified, check the connecting rod oil clearance. 2010 Toyota Prius Repair Manual...
  • Page 55 (g) Examine the front marks and numbers and place the bearing caps on the cylinder block. HINT: A number is marked on each crankshaft bearing cap to indicate the installation position. (h) Install the crankshaft bearing cap 2010 Toyota Prius Repair Manual...
  • Page 56 Then select a new bearing with the calculated number according to the chart below. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly. 2010 Toyota Prius Repair Manual...
  • Page 57 1.998 to 2.000 mm (0.07866 to 0.07874 in.) Mark 3 2.001 to 2.003 mm (0.07878 to 0.07886 in.) Mark 4 2.004 to 2.006 mm (0.07890 to 0.07898 in.) 11. INSPECT CRANKSHAFT BEARING CAP SET BOLT 2010 Toyota Prius Repair Manual...
  • Page 58 If the diameter is less than the minimum, replace the crankshaft bearing cap set bolt. 12. INSPECT CONNECTING ROD BOLT (a) Using a vernier caliper, measure the tension portion diameter of the bolt. Text in Illustration Measurement Area Standard diameter: 2010 Toyota Prius Repair Manual...
  • Page 59 If air leaks, clean or replace the No. 1 oil nozzle. (d) Push the check valve while applying air into A. Check that air passes through B. If air does not pass through B, clean or replace the No. 1 oil nozzle. 2010 Toyota Prius Repair Manual...
  • Page 60 (0.508 to 0.512 in.) to 0.335 in.) 2. REPLACE STRAIGHT PIN NOTICE: It is not necessary to remove a straight pin unless it is being replaced. (a) Using a plastic-faced hammer, tap in the straight pin. 2010 Toyota Prius Repair Manual...
  • Page 61 8 mm (0.315 in.) 5.0 to 7.0 mm (0.197 to 0.276 in.) Pin E 12 mm (0.472 in.) 4 mm (0.156 in.) 5.0 to 6.0 mm (0.197 to 0.236 in.) 3. REPLACE CONNECTING ROD SMALL END BUSH 2010 Toyota Prius Repair Manual...
  • Page 62 0.005 to 0.011 (0.000197 to 0.000433 in.) (e) Coat the piston pin with engine oil. Push the piston pin into the connecting rod with your thumb to check that the piston pin fits at normal room temperature. 2010 Toyota Prius Repair Manual...
  • Page 63 2010 Toyota Prius Repair Manual...
  • Page 64 (a) Using a 5 mm socket hexagon wrench, install the 4 oil nozzles with the 4 bolts. Torque: 10 N·m (102 kgf·cm, 7ft·lbf) 3. INSTALL PISTON (a) Using a screwdriver, install a new snap ring at one end of the piston pin hole. Text in Illustration Service Hole 2010 Toyota Prius Repair Manual...
  • Page 65 (e) Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin. 4. INSTALL PISTON RING SET (a) Install the oil ring expander and oil ring by hand. Text in Illustration 2010 Toyota Prius Repair Manual...
  • Page 66 Securely install the expander to the inner groove of the oil ring. (b) Using a piston ring expander, install the 2 compression rings so that the paint marks are positioned as shown in the illustration. Text in Illustration No. 1 Compression Ring 2010 Toyota Prius Repair Manual...
  • Page 67 Text in Illustration No. 1 compression ring and Oil Ring No. 2 compression ring and Oil Ring Expander Engine Front 5. INSTALL CRANKSHAFT BEARING (a) Install the upper bearing (except No. 3 journal). Text in Illustration 2010 Toyota Prius Repair Manual...
  • Page 68 Standard dimension (A - B): 0.7 mm (0.0276 in.) or less NOTICE: Do not apply engine oil to the bearing or the contact surfaces. (c) Install the lower bearing. (1) Install the upper bearing to the cylinder block. 2010 Toyota Prius Repair Manual...
  • Page 69 (a) Apply engine oil to the upper bearings and install the crankshaft to the cylinder block. (b) Apply engine oil to the lower bearings. (c) Examine the number marks and install the bearing caps to the cylinder block. 2010 Toyota Prius Repair Manual...
  • Page 70 (f) Push on the crankshaft bearing caps with your hand until the clearance between the crankshaft bearing caps and cylinder block is less than 5 mm (0.197 in.). (g) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit. 2010 Toyota Prius Repair Manual...
  • Page 71 (j) Step 2: (1) Mark the front of the bearing cap bolts with paint. Text in Illustration Paint Mark Engine Front (2) Tighten the bearing cap bolts 90° in the sequence shown in step 1. 2010 Toyota Prius Repair Manual...
  • Page 72 Do not apply engine oil to the bearings or the contact surfaces. 9. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD (a) Apply engine oil to the cylinder walls, pistons, and the surfaces of the connecting rod bearings. Text in Illustration No. 1 compression ring and Oil Ring 2010 Toyota Prius Repair Manual...
  • Page 73 (e) Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts. (f) Install the connecting rod cap bolts. NOTICE: The connecting rod cap bolts should be tightened in 2 progressive steps. (g) Step 1: 2010 Toyota Prius Repair Manual...
  • Page 74 (i) Check that the crankshaft turns smoothly. (j) Check the connecting rod thrust clearance 10. INSTALL NO. 1 VENTILATION CASE (a) Apply seal packing in a continuous line as shown in the illustration. Text in Illustration Seal Packing Seal Packing Diameter 2010 Toyota Prius Repair Manual...
  • Page 75 Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Application Specification: Distance from inside edge of cover to Seal Packing Diameter center of seal packing 2.0 to 3.0 mm (0.0787 to 3.0 mm (0.118 in.) 0.118 in.) Remove any oil from the contact surface.
  • Page 76 COMPONENTS ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 77 Arrange the removed parts in the correct order. (c) Remove the retainer, valve spring and valve. HINT: Arrange the removed parts in the correct order. 3. REMOVE VALVE STEM OIL SEAL (a) Using needle-nose pliers, remove the oil seals. 2010 Toyota Prius Repair Manual...
  • Page 78 If water leaks from the straight screw plug or the plug is corroded, replace it. (a) Using a 10 mm straight hexagon wrench, remove the 3 screw plugs and 3 gaskets. 6. REMOVE STUD BOLT NOTICE: If a stud bolt is deformed or its threads are damaged, replace it. 2010 Toyota Prius Repair Manual...
  • Page 79 (a) Using a dye penetrant, check the intake ports, exhaust ports and cylinder surface for cracks. If cracked, replace the cylinder head. 3. INSPECT VALVE SEATS (a) Apply a light coat of Prussian blue to the valve face. Text in Illustration 2010 Toyota Prius Repair Manual...
  • Page 80 4. INSPECT CAMSHAFT THRUST CLEARANCE (a) Install the camshafts (b) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.06 to 0.155 mm (0.00236 to 0.00610 in.) Maximum thrust clearance: 2010 Toyota Prius Repair Manual...
  • Page 81 Camshaft No. 1 Journal 0.030 to 0.063 mm (0.00118 to 0.00248 in.) Camshaft Other Journals 0.035 to 0.072 mm (0.00138 to 0.00283 in.) Maximum Oil Clearance: Item Specified Condition Camshaft No. 1 Journal 0.085 mm (0.00335 in.) 2010 Toyota Prius Repair Manual...
  • Page 82 7. INSPECT INTAKE VALVE (a) Using a vernier caliper, measure the overall length of the valve. Text in Illustration Overall Length Standard overall length: 109.34 mm (4.30 in.) Minimum overall length: 108.84 mm (4.29 in.) 2010 Toyota Prius Repair Manual...
  • Page 83 Standard overall length: 108.25 mm (4.26 in.) Minimum overall length: 107.75 mm (4.24 in.) If the overall length is less than the minimum, replace the valve. (b) Using a micrometer, measure the diameter of the valve stem. 2010 Toyota Prius Repair Manual...
  • Page 84 (b) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement. Standard Oil Clearance: Item Specified Condition Intake 0.025 to 0.060 mm (0.000984 to 0.00236 in.) Exhaust 0.030 to 0.065 mm (0.00118 to 0.00256 in.) Maximum Oil Clearance: 2010 Toyota Prius Repair Manual...
  • Page 85 Item Specified Condition Intake 0.080 mm (0.00315 in.) Exhaust 0.085 mm (0.00335 in.) If the clearance is more than the maximum, replace the valve and guide bush. 2010 Toyota Prius Repair Manual...
  • Page 86 (e) Heat the cylinder head to 80 to 100°C (176 to 212°F). (f) Place the cylinder head on wooden blocks. (g) Using SST and a hammer, tap in a new guide bush to the specified protrusion height. Text in Illustration Height 2010 Toyota Prius Repair Manual...
  • Page 87 SST: 09201-10000 09201-01050 SST: 09950-70010 09951-07100 (d) Using a caliper gauge, measure the bush bore diameter of the cylinder head. Standard cylinder bore diameter: 10.285 to 10.306 mm (0.405 to 0.406 in.) Select New Guide Bush: 2010 Toyota Prius Repair Manual...
  • Page 88 (h) Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard clearance between the guide bush and valve stem. Standard oil clearance: 0.030 to 0.065 mm (0.00118 to 0.00256 in.) 3. REPLACE RING PIN NOTICE: 2010 Toyota Prius Repair Manual...
  • Page 89 Text in Illustration Width Height Protrusion Height Standard Ring Pin: Item Height Width Protrusion Ring 11.7 to 12.3 mm (0.461 12.0 mm 6.5 to 7.5 mm (0.256 to to 0.484 in.) (0.472 in.) 0.295 in.) 2010 Toyota Prius Repair Manual...
  • Page 90 When using a new cylinder head, the spark plug tubes must be replaced. (a) Apply adhesive onto the shaded area of a new spark plug tube. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Standard application width: 1.0 to 3.0 mm (0.0394 to 0.118 in.) Install the spark plug tube within 3 minutes of applying adhesive.
  • Page 91 (a) Using a 10 mm straight hexagon wrench, install 3 new gaskets and the 3 straight screw plugs. Torque: 44 N·m (449 kgf·cm, 32ft·lbf) 4. INSTALL VALVE SPRING SEAT (a) Install the valve spring seats to the cylinder head. 5. INSTALL VALVE STEM OIL SEAL 2010 Toyota Prius Repair Manual...
  • Page 92 (b) Apply engine oil to each valve over an area 30 mm (1.18 in.) or more from its tip, as shown in the illustration. (c) Install the valve, compression spring and spring retainer to the cylinder head. 2010 Toyota Prius Repair Manual...
  • Page 93 (c) Install the valve, compression spring and spring retainer to the cylinder head. NOTICE: Install the same parts in the same combination to the original locations. (d) Using SST, compression spring and install the valve retainer locks. SST: 09202-70020 09202-00010 2010 Toyota Prius Repair Manual...
  • Page 94 (e) Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit. Be careful not to damage the valve stem tip. Be careful not to damage the retainer. 2010 Toyota Prius Repair Manual...
  • Page 95 Standard valve seat width: 1.0 to 1.4 mm (0.0394 to 0.0551 in.) (c) Hand-lap the valve and valve seat with an abrasive compound. (d) Check the valve seating position. 2010 Toyota Prius Repair Manual...
  • Page 96 COMPONENTS ILLUSTRATION ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 97 2010 Toyota Prius Repair Manual...
  • Page 98 (b) Using a screwdriver with its tip wrapped with tape, pry between the cylinder head and cylinder block, and remove the cylinder head. NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block. 9. REMOVE CYLINDER HEAD GASKET (a) Remove the cylinder head gasket. 2010 Toyota Prius Repair Manual...

  • Page 99: Installation

    Cylinder Block Engine Front Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTICE: Remove any oil from the cylinder block. (b) Place a new cylinder head gasket on the cylinder block with the Lot No. stamp facing upward.
  • Page 100 (c) Apply seal packing (Diameter 4.0 mm (0.157 in.)) to the new cylinder head gasket as shown in the illustration. Text in Illustration Cylinder Head Gasket Engine Front Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent 2010 Toyota Prius Repair Manual...
  • Page 101 (1) Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts in several steps, in the sequence shown in the illustration. Torque: 49 N·m (500 kgf·cm, 36ft·lbf) NOTICE: Do not drop the plate washers into the cylinder head. 2010 Toyota Prius Repair Manual...
  • Page 102 9. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 10. INSTALL EXHAUST MANIFOLD 11. INSTALL MANIFOLD STAY 12. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 13. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY (a) Install the camshaft housing sub-assembly 2010 Toyota Prius Repair Manual...
  • Page 103 (a) Put the engine in inspection mode (b) Warm up and stop the engine. (c) When using the Techstream: Check the ignition timing. (1) Connect the Techstream to the DLC3. (2) Put the engine in inspection mode 2010 Toyota Prius Repair Manual...
  • Page 104 (9) Turn the power switch off. (10) Turn the Techstream off. (11) Disconnect the Techstream from the DLC3. (d) When not using the Techstream: (1) Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3. SST: 09843-18040 2010 Toyota Prius Repair Manual...
  • Page 105 (6) Disconnect terminals 13 (TC) and 4 (CG) of the DLC3. (7) Inspect the ignition timing at idle. Standard ignition timing: 0 to 16 degrees BTDC (8) Confirm that the ignition timing advances when the engine rpm is increased. 2010 Toyota Prius Repair Manual...
  • Page 106 (i) Turn the Techstream off. (j) Disconnect the Techstream from the DLC3. 8. INSPECT COMPRESSION (a) Put the engine in inspection mode (b) Warm up and stop the engine. (c) Remove the 4 spark plugs 2010 Toyota Prius Repair Manual...
  • Page 107 If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged. If the pressure stays low, the valve may be stuck or seated improperly, or there may be leaks from the gasket. 2010 Toyota Prius Repair Manual...
  • Page 108 3. Leaks from intake and exhaust valves 4. Leaks from cylinders 5. Faulty EGR 1. Vacuum leaks: PCV hoses Rough idle (Fluctuating HC Intake manifold Low High reading) Throttle body Brake booster line 2. Lean mixture causing misfire 2010 Toyota Prius Repair Manual...
  • Page 109 2. Plugged PCV valve 3. Faulty EFI systems: Faulty pressure regulator Faulty engine coolant temperature sensor Rough idle (Black smoke from High High Faulty mass air flow meter exhaust) Faulty ECM Faulty injectors Throttle body 4. Faulty EGR 2010 Toyota Prius Repair Manual...
  • Page 110 COMPONENTS ILLUSTRATION ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 111 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 112 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 113 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 114 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 115 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 116 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 117 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 118 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 119 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 120 2010 Toyota Prius Repair Manual...
  • Page 121 13. REMOVE ENGINE UNDER COVER (w/ Cover) 14. REMOVE NO. 1 ENGINE UNDER COVER 15. REMOVE NO. 2 ENGINE UNDER COVER 16. DRAIN ENGINE OIL 17. DRAIN COOLANT (for Engine) 18. DRAIN COOLANT (for Inverter) 19. DRAIN HYBRID TRANSAXLE FLUID 2010 Toyota Prius Repair Manual...
  • Page 122 NOTICE: Attempting to disengage both front and rear clips at the same time may cause the cover to break. 30. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (a) Disconnect the air flow meter connector. 2010 Toyota Prius Repair Manual...
  • Page 123 (b) Remove the 3 bolts and air cleaner case. 33. REMOVE AIR CLEANER HOSE ASSEMBLY 34. REMOVE RADIATOR SUPPORT OPENING COVER 35. REMOVE NO. 1 INVERTER BRACKET 36. DISCONNECT ENGINE ROOM MAIN WIRE 37. REMOVE INVERTER TERMINAL COVER 2010 Toyota Prius Repair Manual...
  • Page 124 47. REMOVE INVERTER TRAY BRACKET (a) Separate the 2 clamps. (b) Remove the 5 bolts and inverter tray bracket. 48. DISCONNECT NO. 1 RADIATOR HOSE (a) Disconnect the No. 1 radiator hose from the radiator pipe assembly. 2010 Toyota Prius Repair Manual...
  • Page 125 51. DISCONNECT NO. 3 INVERTER COOLING HOSE (a) Disconnect the No. 3 inverter cooling hose from the hybrid transaxle assembly. 52. DISCONNECT NO. 5 INVERTER COOLING HOSE (a) Disconnect the No. 5 inverter cooling hose from the hybrid transaxle 2010 Toyota Prius Repair Manual...
  • Page 126 54. DISCONNECT INLET HEATER WATER HOSE (a) Disconnect the inlet heater water hose. 55. DISCONNECT HEATER HOSE (a) Disconnect the heater hose. 56. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE (a) Disconnect the No. 1 fuel vapor feed hose. 2010 Toyota Prius Repair Manual...
  • Page 127 Protect the disconnected parts by covering them with plastic bags after disconnecting the fuel tube. If the fuel tube connector and pipe are stuck, push and pull to release them. 58. SEPARATE ELECTRIC INVERTER COMPRESSOR 59. DISCONNECT WIRE HARNESS (a) Disconnect the 2 clamps. 2010 Toyota Prius Repair Manual...
  • Page 128 (d) Disconnect the 3 clamps. (e) Remove the bolt and disconnect the earth wire. (f) Disconnect the 2 clamps and wire harness. 60. SECURE STEERING WHEEL 61. REMOVE COLUMN HOLE COVER SILENCER SHEET 2010 Toyota Prius Repair Manual...
  • Page 129 76. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH HINT: Perform the same procedure as for the LH side. 77. SEPARATE FRONT NO. 1 LOWER SUSPENSION ARM SUB-ASSEMBLY LH 78. SEPARATE FRONT NO. 1 LOWER SUSPENSION ARM SUB-ASSEMBLY RH 2010 Toyota Prius Repair Manual...
  • Page 130 89. REMOVE FRONT SUSPENSION MEMBER REAR BRACE RH HINT: Perform the same procedure as for the LH side. 90. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 91. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (a) Set the engine lifter. 2010 Toyota Prius Repair Manual...
  • Page 131 (e) Carefully remove the engine with transaxle from the vehicle. (f) Install the 2 engine hangers with the 2 bolts. Torque: 43 N·m (438 kgf·cm, 32ft·lbf) Part Name Part No. No. 1 engine hanger 12281-37021 No. 2 engine hanger 12282-37011 Bolt 91552-81050 2010 Toyota Prius Repair Manual...
  • Page 132 (b) Remove the front engine mounting insulator from the front engine mounting bracket. 93. REMOVE FRONT ENGINE MOUNTING INSULATOR (a) Remove the 2 bolts and front engine mounting insulator. 94. REMOVE REAR ENGINE MOUNTING INSULATOR (a) Remove the through bolt, and separate the rear engine mounting 2010 Toyota Prius Repair Manual...
  • Page 133 (a) Remove the 3 bolts and 2 cooler brackets. (b) Remove the 3 bolts and engine mounting insulator sub-assembly RH. 97. REMOVE RADIATOR PIPE (a) Separate the No. 3 radiator hose from the cylinder head. 2010 Toyota Prius Repair Manual...
  • Page 134 (b) Remove the transmission input damper assembly 103. REMOVE FLYWHEEL SUB-ASSEMBLY (a) Gently place the engine assembly onto wood blocks or equivalent. NOTICE: This step should be done while hanging the engine assembly using the engine hangers and a chain block. 2010 Toyota Prius Repair Manual...
  • Page 135 (b) Remove the flywheel sub-assembly 2010 Toyota Prius Repair Manual...

  • Page 136: Installation

    4. INSTALL ENGINE WIRE 5. INSTALL STARTER HOLE INSULATOR 6. INSTALL FLYWHEEL HOUSING SIDE COVER 7. INSTALL RADIATOR PIPE (a) Install the radiator pipe with the 2 bolts. Torque: 19 N·m (194 kgf·cm, 14ft·lbf) 2010 Toyota Prius Repair Manual...
  • Page 137 (c) Tighten the 3 bolts to the engine mounting insulator sub-assembly RH in the order the bolt B, bolt C and bolt Torque: 95 N·m (969 kgf·cm, 70ft·lbf) (d) Install the 2 cooler brackets with the 2 bolts. Torque: 9.8 N·m (100 kgf·cm, 87in·lbf) 9. INSTALL ENGINE MOUNTING INSULATOR LH 2010 Toyota Prius Repair Manual...
  • Page 138 12. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (a) Set the engine assembly with transaxle on the engine lifter. NOTICE: Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle. 2010 Toyota Prius Repair Manual...
  • Page 139 Make sure that the engine is clear of all wiring and hoses. While raising the engine into the vehicle, do not allow it to contact the vehicle. (e) Install the front crossmember with the 4 bolts. 2010 Toyota Prius Repair Manual...
  • Page 140 Bolt - Torque: 95 N·m (969 kgf·cm, 70ft·lbf) (i) Tighten the front engine mounting insulator with the bolt and nut. Torque: 145 N·m (1479 kgf·cm, 107ft·lbf) 13. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 14. INSTALL FRONT SUSPENSION MEMBER REAR BRACE LH 2010 Toyota Prius Repair Manual...
  • Page 141 25. INSTALL FRONT STABILIZER LINK ASSEMBLY LH 26. INSTALL FRONT STABILIZER LINK ASSEMBLY RH HINT: Perform the same procedure as for the LH side. 27. CONNECT TIE ROD END SUB-ASSEMBLY LH 28. CONNECT TIE ROD END SUB-ASSEMBLY RH HINT: 2010 Toyota Prius Repair Manual...
  • Page 142 39. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY 40. INSTALL COLUMN HOLE COVER SILENCER SHEET 41. INSTALL WIRE HARNESS (a) Connect the wire harness with the 2 clamps. (b) Install the wire harness with the bolt. 2010 Toyota Prius Repair Manual...
  • Page 143 (e) Connect the 2 connectors to the engine room junction block. (f) Connect the connector to the ECM with the 2 clamps and lock lever. 42. INSTALL ELECTRIC INVERTER COMPRESSOR 43. CONNECT FUEL TUBE SUB-ASSEMBLY (a) Connect the fuel tube connector and fuel pipe. 2010 Toyota Prius Repair Manual...
  • Page 144 (a) Connect the No. 1 fuel vapor feed hose with the clamp. 45. CONNECT HEATER HOSE (a) Connect the heater hose with the clamp. 46. CONNECT INLET HEATER WATER HOSE (a) Connect the inlet heater water hose with the clamp. 2010 Toyota Prius Repair Manual...
  • Page 145 49. CONNECT NO. 3 INVERTER COOLING HOSE (a) Connect the No. 3 inverter cooling hose with the clamp. 50. CONNECT NO. 4 WATER BY-PASS HOSE (a) Connect the No. 4 water by-pass hose with the clamp. 2010 Toyota Prius Repair Manual...
  • Page 146 (b) Temporarily install bolt B to the inverter tray bracket. (c) Tighten the 5 bolts to the inverter tray bracket in the order the bolt A, bolt C, bolt D, bolt E and bolt B. 2010 Toyota Prius Repair Manual...
  • Page 147 63. INSTALL INVERTER TERMINAL COVER 64. CONNECT ENGINE ROOM MAIN WIRE 65. INSTALL NO. 1 INVERTER BRACKET 66. INSTALL AIR CLEANER HOSE ASSEMBLY 67. INSTALL AIR CLEANER CASE (a) Install the air cleaner case with the 3 bolts. 2010 Toyota Prius Repair Manual...
  • Page 148 (c) Connect the No. 4 water by-pass hose to the inlet air cleaner assembly with the clamp. 69. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (a) Install the air cleaner cap sub-assembly with the 2 clamps and hose band. 2010 Toyota Prius Repair Manual...
  • Page 149 86. INSTALL NO. 2 ENGINE UNDER COVER 87. INSTALL NO. 1 ENGINE UNDER COVER 88. INSTALL ENGINE UNDER COVER (w/ Cover) 89. INSTALL FRONT SPOILER COVER (w/ Front Spoiler) 90. INSTALL REAR ENGINE UNDER COVER LH 2010 Toyota Prius Repair Manual...
  • Page 150 103. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY LH 104. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY RH 105. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH 106. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH 107. INSTALL FRONT WIPER ARM HEAD CAP 2010 Toyota Prius Repair Manual...
  • Page 151 108. CHECK ABS SPEED SENSOR SIGNAL HINT: 2010 Toyota Prius Repair Manual...
  • Page 152 COMPONENTS ILLUSTRATION ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 153 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 154 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 155 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 156 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 157 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 158 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 159 2010 Toyota Prius Repair Manual...
  • Page 160 5. REMOVE EGR PIPE ASSEMBLY 6. REMOVE EGR VALVE ASSEMBLY 7. REMOVE EGR WITH COOLER PIPE SUB-ASSEMBLY 8. REMOVE INTAKE MANIFOLD 9. REMOVE FUEL VAPOR FEED PIPE (a) Remove the bolt and fuel vapor feed pipe. 2010 Toyota Prius Repair Manual...
  • Page 161 12. REMOVE FUEL INJECTOR ASSEMBLY 13. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 14. REMOVE MANIFOLD STAY 15. REMOVE EXHAUST MANIFOLD 16. REMOVE VENTILATION HOSE (a) Remove the ventilation hose from the ventilation valve. 17. REMOVE IGNITION COIL ASSEMBLY 2010 Toyota Prius Repair Manual...
  • Page 162 (a) Remove the oil filler cap gasket. 3. REMOVE ENGINE COVER JOINT BOLT (a) Remove the 3 engine cover joint bolts. 4. REMOVE WIRING HARNESS CLAMP BRACKET (a) Remove the bolt and wiring harness clamp bracket. 2010 Toyota Prius Repair Manual...
  • Page 163 7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Remove the bolt and camshaft timing oil control valve. (b) Remove the O-ring from the camshaft timing oil control valve. 8. REMOVE CRANKSHAFT POSITION SENSOR (a) Remove the bolt and crankshaft position sensor. 2010 Toyota Prius Repair Manual...
  • Page 164 (a) Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly. 10. REMOVE KNOCK SENSOR (a) Remove the bolt and knock sensor. 11. REMOVE ENGINE COOLANT TEMPERATURE SENSOR (a) Remove the engine coolant temperature sensor and gasket. 2010 Toyota Prius Repair Manual...
  • Page 165 (a) Remove the cylinder head cover gasket. 14. REMOVE SPARK PLUG TUBE GASKET (a) Pry up the 4 claws of the ventilation baffle plate. NOTICE: Do not deform the claws of the baffle plate more than necessary. 2010 Toyota Prius Repair Manual...
  • Page 166 (a) Remove the bolt, 2 nuts, inlet water sub-assembly and gasket. 17. REMOVE INLET WATER SUB-ASSEMBLY STUD BOLT NOTICE: If a stud bolt is deformed or its threads are damaged, replace it. 18. SET NO. 1 CYLINDER TO TDC/COMPRESSION 19. REMOVE CRANKSHAFT PULLEY 2010 Toyota Prius Repair Manual...
  • Page 167 (a) Using a screwdriver, remove the 2 crankshaft timing gear keys. Text in Illustration Protective Tape HINT: Tape the screwdriver tip before use. 31. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY 32. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY 2010 Toyota Prius Repair Manual...
  • Page 168 (a) Remove the 16 valve lash adjusters from the cylinder head. HINT: Arrange the removed parts in the correct order. 40. REMOVE VALVE STEM CAP (a) Remove the 16 valve stem caps. HINT: Arrange the removed parts in the correct order. 2010 Toyota Prius Repair Manual...
  • Page 169 (a) Remove the oil control valve filter from the No. 1 camshaft bearing cap. 42. REMOVE NO. 1 CAMSHAFT BEARING (a) Remove the 2 camshaft bearings 43. REMOVE NO. 2 CAMSHAFT BEARING (a) Remove the 2 camshaft bearings. 2010 Toyota Prius Repair Manual...
  • Page 170 (a) Remove the drain cock plug from the drain cock. (b) Remove the drain cock from the cylinder block. 48. REMOVE VENTILATION VALVE SUB-ASSEMBLY (a) Remove the ventilation valve sub-assembly. 49. REMOVE OIL PAN DRAIN PLUG (a) Remove the drain plug and gasket. 2010 Toyota Prius Repair Manual...
  • Page 171 Text in Illustration Protective Tape HINT: Tape the screwdriver tip before use. NOTICE: Be careful not to damage the contact surfaces of the crankcase and cylinder block. 53. REMOVE ENGINE REAR OIL SEAL 2010 Toyota Prius Repair Manual...
  • Page 172 NOTICE: If a stud bolt is deformed or its threads are damaged, replace it. 56. REMOVE STIFFENING CRANKCASE RING PIN NOTICE: It is not necessary to remove a ring pin unless it is being replaced. 2010 Toyota Prius Repair Manual...
  • Page 173 (b) Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger. Text in Illustration Plunger Check Ball Low Pressure Chamber High Pressure Chamber CORRECT INCORRECT Taper Part SST: 09276-75010 2010 Toyota Prius Repair Manual...
  • Page 174 (e) After bleeding the air, remove SST. Then try to quickly and firmly press the plunger with your fingers. Plunger can be pressed 3 times. If the plunger can still be compressed after pressing it 3 times, replace the valve lash adjuster with a new one. 3. INSPECT CHAIN SUB-ASSEMBLY 2010 Toyota Prius Repair Manual...
  • Page 175 Perform the measurement at 3 random places. Use the average of the measurements. If the average elongation is more than the maximum, replace the No. 2 chain sub-assembly. 5. INSPECT OIL PUMP DRIVE GEAR (a) Place the chain around the oil pump drive gear. 2010 Toyota Prius Repair Manual...
  • Page 176 The vernier caliper must be in contact with the chain rollers when measuring. If the diameter is less than the minimum, replace the chain and oil pump drive shaft gear. 7. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY (a) Place the chain around the camshaft timing gear assembly. 2010 Toyota Prius Repair Manual...
  • Page 177 The vernier caliper must be in contact with the chain rollers when measuring. If the diameter is less than the minimum, replace the chain and camshaft timing sprocket. 9. INSPECT CRANKSHAFT TIMING GEAR (a) Place the chain around the crankshaft timing gear. 2010 Toyota Prius Repair Manual...
  • Page 178 1.0 mm (0.0394 in.) If the wear is more than the maximum, replace the No. 1 chain vibration damper. 12. INSPECT NO. 2 CHAIN VIBRATION DAMPER (a) Using a vernier caliper, measure the No. 2 chain vibration damper 2010 Toyota Prius Repair Manual...
  • Page 179 If necessary, replace the No. 1 chain tensioner. 15. INSPECT CAMSHAFT (a) Inspect the camshaft for runout. (1) Place the camshaft on V-blocks. (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 2010 Toyota Prius Repair Manual...
  • Page 180 (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.04 mm (0.00157 in.) If the circle runout is more than the maximum, replace the No. 2 camshaft. (b) Inspect the cam lobes. 2010 Toyota Prius Repair Manual...
  • Page 181 Maximum length: 149.2 mm (5.87 in.) If the length is more than the maximum, replace the cylinder head set bolt. (b) Using a vernier caliper, measure the diameter of the elongated thread at the measurement point. 2010 Toyota Prius Repair Manual...
  • Page 182 (a) Using a precision straightedge and feeler gauge, measure the warpage on the surface that contacts the cylinder head. Maximum warpage: 0.7 mm (0.0276 in.) If the warpage is more than the maximum, replace the exhaust manifold. 2010 Toyota Prius Repair Manual...
  • Page 183 Torque: 5.0 N·m (51 kgf·cm, 44in·lbf) 3. INSTALL STIFFENING CRANKCASE ASSEMBLY (a) Apply seal packing in a continuous line as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three bond 1207B or equivalent Standard Seal Diameter: Area Specified Condition...
  • Page 184 (d) Wipe off any excess seal packing with a clean piece of cloth. 4. INSTALL OIL PUMP ASSEMBLY 5. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY 6. INSTALL OIL PAN DRAIN PLUG (a) Install a new gasket and the drain plug. Torque: 37 N·m (377 kgf·cm, 27ft·lbf) 2010 Toyota Prius Repair Manual...
  • Page 185 Text in Illustration Adhesive Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent (b) Install the drain cock as shown in the illustration. Torque: 25 N·m (255 kgf·cm, 18ft·lbf) Do not rotate the drain cock more than 1 revolution (360°) after tightening it to the specified torque.
  • Page 186 Adhesive Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent (b) Install the taper screw plug. Torque: 43 N·m (438 kgf·cm, 32ft·lbf) Install the plug within 3 minutes of applying adhesive. Do not start the engine for at least 1 hour after installation.
  • Page 187 It is not necessary to remove a straight pin unless it is being replaced. (a) Using a plastic-faced hammer, tap in a new straight pin to the specified protrusion height. Text in Illustration Width Height 2010 Toyota Prius Repair Manual...
  • Page 188 20. INSTALL NO. 2 CAMSHAFT 21. INSTALL CAMSHAFT 22. INSTALL CAMSHAFT BEARING CAP 23. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY 24. INSTALL CAMSHAFT TIMING SPROCKET 25. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 26. INSTALL CRANKSHAFT TIMING GEAR KEY 2010 Toyota Prius Repair Manual...
  • Page 189 If a stud bolt is deformed or the threads are damaged, replace it. (a) Using an E5 "TORX" socket wrench, install the stud bolts as shown in the illustration. Torque: 5.0 N·m (51 kgf·cm, 44in·lbf) 2010 Toyota Prius Repair Manual...
  • Page 190 40. INSTALL CRANKSHAFT PULLEY 41. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 42. INSTALL OIL FILTER CAP ASSEMBLY 43. INSTALL SPARK PLUG TUBE GASKET (a) Using a cutter knife, cut off the seal part of the removed gasket. 2010 Toyota Prius Repair Manual...
  • Page 191 (a) Install a new cylinder head cover gasket to the cylinder head cover. Text in Illustration Cylinder Head Cover Cylinder Head Cover Gasket Remove any oil from the contact surfaces. Misalignment between the center of the cylinder head cover rib 2010 Toyota Prius Repair Manual...
  • Page 192 (a) Install 2 new gaskets to the camshaft bearing cap. (b) Apply seal packing as shown the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard diameter: 4.0 mm (0.157 in.) Remove any oil from the contact surfaces.
  • Page 193 Timing Chain Cover Camshaft Housing Cylinder Head Cover Gasket 46. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY (a) Apply adhesive to 2 or 3 threads of the engine oil pressure switch assembly. Text in Illustration Adhesive 2010 Toyota Prius Repair Manual...
  • Page 194 Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent Install the oil pressure switch within 3 minutes after applying adhesive. Do not start the engine within 1 hour after installation. (b) Using a 24 mm deep socket wrench, install the engine oil pressure switch assembly.
  • Page 195 Be careful that the O-ring is not cracked or moved out of place when installing the oil control valve. 51. INSTALL CAMSHAFT POSITION SENSOR (a) Apply a light coat of engine oil to the O-ring of the sensor. 2010 Toyota Prius Repair Manual...
  • Page 196 54. INSTALL WIRING HARNESS CLAMP BRACKET (a) Install the wiring harness clamp bracket with the bolt. Torque: 10 N·m (102 kgf·cm, 7ft·lbf) 55. INSTALL OIL FILLER CAP GASKET (a) Install the gasket to the oil filler cap. 2010 Toyota Prius Repair Manual...
  • Page 197 56. INSTALL OIL FILLER CAP SUB-ASSEMBLY (a) Install the oil filler cap. 2010 Toyota Prius Repair Manual...

  • Page 198: Installation

    9. INSTALL FUEL VAPOR FEED PIPE (a) Install the fuel vapor feed pipe with the bolt. Torque: 21 N·m (214 kgf·cm, 15ft·lbf) 10. INSTALL INTAKE MANIFOLD 11. INSTALL EGR WITH COOLER PIPE SUB-ASSEMBLY 12. INSTALL EGR VALVE ASSEMBLY 2010 Toyota Prius Repair Manual...
  • Page 199 (a) Install the 2 engine hangers with the 2 bolts. Torque: 43 N·m (438 kgf·cm, 32ft·lbf) Part Name Part No. No. 1 engine hanger 12281-37021 No. 2 engine hanger 12282-37011 Bolt 91552-81050 17. REMOVE ENGINE ON ENGINE STAND 2010 Toyota Prius Repair Manual...
  • Page 200 (a) Remove the bolts and engine on engine stand. 2010 Toyota Prius Repair Manual...
  • Page 201 COMPONENTS ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 202 (b) Using SST, remove the crankshaft pulley and pulley bolt. Text in Illustration Hold Turn SST: 09950-50013 09951-05010 09952-05010 09953-05020 09954-05021 HINT: If necessary, remove the pulley and pulley bolt using SST. 5. REMOVE TIMING CHAIN COVER OIL SEAL 2010 Toyota Prius Repair Manual...
  • Page 203 (b) Using a screwdriver with its tip wrapped with tape, pry out the oil seal. Text in Illustration Cut Position NOTICE: After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper. 2010 Toyota Prius Repair Manual...
  • Page 204 (b) Using SST, hold the pulley in place and tighten the bolt. Text in Illustration Hold Turn SST: 09213-58014 91551-80840 SST: 09330-00021 Torque: 190 N·m (1937 kgf·cm, 140ft·lbf) 3. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH 4. INSTALL FRONT WHEEL RH 2010 Toyota Prius Repair Manual...
  • Page 205 Torque: 103 N·m (1050 kgf·cm, 76ft·lbf) 5. INSPECT FOR OIL LEAK 6. INSTALL REAR ENGINE UNDER COVER RH 2010 Toyota Prius Repair Manual...
  • Page 206 COMPONENTS ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 207 SST: 09213-58014 91551-80840 SST: 09330-00021 (b) Remove the 6 bolts and transmission input damper assembly from the flywheel sub-assembly. 3. REMOVE FLYWHEEL SUB-ASSEMBLY (a) Using SST, hold the crankshaft damper. SST: 09213-58014 91551-80840 SST: 09330-00021 2010 Toyota Prius Repair Manual...
  • Page 208 Protective Tape Cut Position (b) Using a screwdriver with its tip wrapped with tape, pry out the oil seal. NOTICE: After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper. 2010 Toyota Prius Repair Manual...
  • Page 209 (a) Using SST, hold the crankshaft. SST: 09213-58014 91551-80840 SST: 09330-00021 (b) Apply adhesive to the 2 or 3 end threads of the bolts. Text in Illustration Adhesive Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 2010 Toyota Prius Repair Manual...
  • Page 210 (f) Check that the paint marks are now at a 90° angle to the front. (g) Check that the crankshaft turns smoothly. 3. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY (a) Using SST, hold the crankshaft. SST: 09213-58014 91551-80840 SST: 09330-00021 2010 Toyota Prius Repair Manual...
  • Page 211 Be careful not to apply excess force to the transmission input damper assembly when removing or installing the hybrid vehicle transaxle assembly. If excess force is applied, the transmission input damper assembly may be damaged, or its splines may become misaligned. 2010 Toyota Prius Repair Manual...
  • Page 212 COMPONENTS ILLUSTRATION ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 213 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 214 2010 Toyota Prius Repair Manual...
  • Page 215 (b) Disconnect the 4 connectors. (c) Remove the bolt. (d) Detach the 2 clamps to disconnect the wire harness. 8. DISCONNECT FUEL TUBE SUB-ASSEMBLY (a) Release the claw and remove the No. 1 fuel pipe clamp. 2010 Toyota Prius Repair Manual...
  • Page 216 (b) Remove the 2 bolts and the fuel delivery pipe sub-assembly. NOTICE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe. 10. REMOVE NO. 1 DELIVERY PIPE SPACER (a) Remove the 2 delivery pipe spacers from the cylinder head. 2010 Toyota Prius Repair Manual...
  • Page 217 (b) Remove the O-ring from each fuel injector. (c) For reinstallation, attach a tag or label to each injector shaft. NOTICE: Prevent entry of foreign objects by covering the fuel injectors with plastic bags. (d) Remove the 4 injector vibration insulators. 2010 Toyota Prius Repair Manual...
  • Page 218 (vehicle side). Text in Illustration SST (Hose) Fuel Pipe (Vehicle Side) SST (Clip) SST (Fuel Tube Connector) SST: 09268-31012 90467-13001 95336-08070 09268-41500 NOTICE: Ensure that the SST connector O-rings are not damaged and are free of 2010 Toyota Prius Repair Manual...
  • Page 219 Test each injector 2 or 3 times. SST: 09842-30080 Standard Injection Volume: Tester Connection Condition Specified Condition Positive terminal - Ground Per 15 60 to 73 cc (3.7 to 4.5 terminal seconds cu.in.) 2010 Toyota Prius Repair Manual...
  • Page 220 (1) In the condition above, disconnect the test probes of SST (wire) from the battery and check the fuel leaks from the injector. Standard fuel drop: 1 drop or less every 25 minutes If the injection volume is not as specified, replace the injector assembly. 2010 Toyota Prius Repair Manual...
  • Page 221 (a) Install the fuel delivery pipe sub-assembly with the 4 fuel injector assemblies and install the 2 bolts. Torque: 21 N·m (214 kgf·cm, 15ft·lbf) Do not drop the fuel injectors when installing the fuel delivery pipe sub-assembly. 2010 Toyota Prius Repair Manual...
  • Page 222 (b) Engage the lock claw to install the No. 1 fuel pipe clamp. 5. CONNECT ENGINE WIRE (a) Install the bolt. Torque: 10 N·m (102 kgf·cm, 7ft·lbf) (b) Connect the 4 fuel injector connectors. (c) Connect the 4 connectors. 2010 Toyota Prius Repair Manual...
  • Page 223 9. INSTALL REAR NO. 2 FLOOR BOARD (for Separate Type) 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTICE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected 11. INSPECT FOR FUEL LEAK 2010 Toyota Prius Repair Manual...