Toyota Prius 2002-06

Oil Pan

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable. Wait at least 90 seconds after disconnecting the negative battery cable to prevent possible airbag and seat belt pretensioner activation.
  4.  
  5. Drain engine oil.
  6.  
  7. Remove engine assembly.
  8.  
  9. Install engine to engine stand.
  10.  
  11. Remove the timing chain.
  12.  
  13. Remove the cylinder head.
  14.  
  15. Remove engine wire.
  16.  
  17. Remove the 2 nuts, bolt and water bypass pipe.
  18.  
  19. Remove the thermostat.
  20.  
  21. Remove the knock sensor.
  22.  
  23. Remove the oil pressure switch.
  24.  
  25. Remove the engine coolant drain union.
  26.  
  27. Remove the oil filter.
  28.  
  29. Using a 12mm hexagon wrench, remove the oil filter union.
  30.  
  31. Remove the 9 bolts and 2 nuts of the No. 2 oil pan.
  32.  
  33. Insert the blade of SST 09032-00100 between the oil pan No. 1 and oil pan No. 2, and cut off applied sealer and remove the oil pan. Be careful not to the damage the oil pan contact surface of the oil pan No. 1. or the oil pan No. 2 flange.
  34.  
  35. Remove the bolt and 2 nuts, oil strainer and gasket.
  36.  
  37. Uniformly loosen and remove the 13 bolts, in several passes.
  38.  
  39. Using screwdriver remove the oil pan No. 1 by prying the portions between the cylinder block and oil pan No. 1.
  40.  
  41. Remove the 2 O-rings from the cylinder block.
  42.  

To install:

  1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the oil pan No. 1 and cylinder block. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. Thoroughly clean all components to remove all the loose material. Using a non-residue solvent, clean both sealing surfaces.

    Click image to see an enlarged view

    Fig. Oil pan No. 1 seal width-1.5L hybrid engine

  2.  
  3. Apply seal packing to the oil pan No. 1 with a seal width of 0.08-0.12 inch (2-3mm). Avoid applying an excessive amount to the surface. Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap.
  4.  
  5. Install new O-rings to the cylinder block.
  6.  
  7. Using a plastic-faced hammer, lightly tap the oil pan No. 1 to ensure a proper fit.

    Click image to see an enlarged view

    Fig. Oil pan No. 1 bolt identification and tightening sequence-1.5L hybrid engine

  8.  
  9. Install and uniformly tighten the 13 bolts, in several passes, in sequence to 18 ft. lbs. (24 Nm).
  10.  
  11. Each bolt indicated in the illustration shown is the following length:

    Bolt A-1.929 inches (49mm)
     
    Bolt B-3.465 inches (88mm)
     
    Bolt C-5.669 inches (144mm)
     

  12.  
  13. Install rear crankshaft oil seal. Wipe seal packing away from the contact surface of the cylinder block assembly and oil seal.
  14.  
  15. Install a new gasket, and oil strainer with the bolt and 2 nuts. Tighten the bolt and 2 nuts to 8 ft. lbs. (11 Nm).
  16.  
  17. Remove any old FIPG material and be careful not to drop any oil on the contact surface of the main bearing cap and oil pan. Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces and sealing grooves. Thoroughly clean all components to remove all the loose material. Using a non-residue solvent, clean both sealing surfaces.

    Click image to see an enlarged view

    Fig. Correct oil pan seal width-1.5L hybrid engine

  18.  
  19. Apply seal packing to the oil pan with a seal width of 0.098-0.138 inch (2.5-3.5mm). Avoid applying an excessive amount to the surface. Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap.
  20.  
  21. Install the oil pan with the 9 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes to 80 inch lbs. (9 Nm).
  22.  
  23. Install the oil filter union and tighten to 21 ft. lbs. (30 Nm).
  24.  
  25. Install the oil filter.
  26.  
  27. Apply adhesive to 2 or 3 threads and install the engine coolant drain union. Torque the union to 25 ft. lbs. (35 Nm) and after applying the specified torque, rotate the drain union clockwise until its drain port is facing downward.
  28.  
  29. Install the knock sensor and tighten to 29 ft. lbs. (39 Nm).
  30.  
  31. Install the oil pressure switch.
  32.  
  33. Install the thermostat.
  34.  
  35. Install the water bypass pipe and tighten bolts to 80 inch lbs. (9 Nm)
  36.  
  37. Install the engine wire.
  38.  
  39. Install the cylinder head.
  40.  
  41. Install the timing chain.
  42.  
  43. Remove the engine assembly from the engine stand.
  44.  
  45. Install the engine assembly into the vehicle.
  46.  
  47. Refill the engine with oil.
  48.  
  49. Connect the negative battery cable.
  50.  
  51. Start the engine and check for leaks.
  52.  

 
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