Toyota Prius 2002-06

Timing Chain & Sprockets

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Removal & Installation





Click image to see an enlarged view

Fig. Exploded view of timing cover, timing chain assembly and related components-1.5L hybrid engine


CAUTION
The hybrid system uses high voltage circuits, so improper handling could cause electric shock or leakage. During service, be sure to follow procedures.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. 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.
  6.  
  7. While wearing insulating gloves, slide up the lever of the service plug grip and remove while turning the lever to the left. Be sure to insulate the service plug with insulating tape.
    CAUTION
    Do not touch the high voltage connectors and terminals for 5 minutes after removing the service plug grip.

  8.  
  9. Remove the outer front cowl top panel.
  10.  
  11. Remove right engine under cover.
  12.  
  13. Drain the engine coolant.
  14.  
  15. Remove or disconnect the following:

    Air cleaner assembly
     
    Brake fluid level sensor connector
     
    Brake fluid reservoir tank mounting bolts (2) and suspend it with rope
     
    Brake fluid reservoir tank bracket
     
    Ignition connectors (4)
     
    Fuel injector connectors (4)
     
    Vacuum Switching Valve (VSV) connectors (2)
     
    Camshaft Position (CMP) sensor connector
     
    Water temperature connector
     
    Camshaft timing oil control valve connector
     
    Air cleaner inlet hose
     
    Engine coolant reservoir tank
     
    VSV from engine mounting insulator
     
    Accessory drive belt
     

  16.  
  17. Place a floor jack under the engine to support it, with a block of wood between the engine and the jack.
  18.  
  19. Remove or disconnect the following:

    Right engine mounting insulator
     
    Engine wiring from cylinder head cover
     
    Ignition coils (4)
     
    PCV hoses (2)
     
    7 bolts, 2 seal washers, 2 nuts, cylinder head cover and gasket
     

  20.  
  21. Set the No. 1 cylinder to Top Dead Center/compression by turning the crankshaft pulley and aligning its groove with timing mark -0- of the timing chain cover.

    Click image to see an enlarged view

    Fig. Aligning both timing marks on the camshaft timing sprocket and valve timing controller assembly-1.5L hybrid engine

  22.  
  23. Check that both timing marks on the camshaft timing sprocket and valve timing controller assembly are facing right up. If not, turn the crankshaft 1 revolution (360 degrees) and align the marks.
  24.  
  25. Remove the crankshaft pulley bolt and the crankshaft pulley.
  26.  
  27. Remove or disconnect the following:

    Crankshaft Position (CKP) sensor
     
    Right engine mounting bracket
     
    Water pump
     
    Oil control valve
     
    Timing chain cover
     
    Chain tensioner
     
    Chain tensioner slipper
     
    Chain vibration damper
     
    Timing chain
     

  28.  

To install:

  1. Install the timing chain.
  2.  
  3. After setting the crankshaft at ATDC 40-140 degrees, set cams of intake and exhaust timing sprockets at ATDC 20 degrees and then the reset the crankshaft at ATDC 20 degrees.
  4.  
  5. Install the chain vibration damper with the 2 bolts and tighten to 80 inch lbs. (9 Nm).

    Click image to see an enlarged view

    Fig. Align the match marks of timing chain mark plate (Yellow), camshaft timing sprocket, camshaft timing gear and crankshaft timing sprocket-1.5L hybrid engine

  6.  
  7. Align the match marks of timing chain mark plate (Yellow), camshaft timing sprocket, camshaft timing gear and crankshaft timing sprocket to install the timing chain. To prevent the exhaust camshaft from spring back, turn it using a wrench and set it at the mark on a chain.
  8.  
  9. Install the chain tensioner slipper.
  10.  
  11. While rotating the lock plate of the tensioner up-ward, push in the plunger of the tensioner.
  12.  
  13. While rotating the lock plate of the tensioner down-ward, insert a bar of 0.098 inch (2.5mm) into the holes in the lock plate.
  14.  
  15. Install the chain tensioner with the 2 bolts and tighten to 80 inch lbs. (9 Nm).
  16.  
  17. Remove the bar from the chain tensioner.
  18.  
  19. Check that the tension between the intake and exhaust camshaft timing sprocket.

    Click image to see an enlarged view

    Fig. Apply seal packing to the timing chain cover-1.5L hybrid engine

  20.  
  21. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block. Using a razor blade and a 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.
  22.  
  23. Apply seal packing to the timing chain cover. Install a nozzle that has been cut to a 0.16-0.20 inch (4-5mm) opening. FIPG shall be accumulated in the groove for FIPG to a depth of 0.10 inch (2.5mm) or more. 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.

    Click image to see an enlarged view

    Fig. Apply seal packing to 4 locations-1.5L hybrid engine

  24.  
  25. Apply seal packing to 4 locations. Install a nozzle that has been cut to a 0.16-0.20 inch (4-5mm) opening. 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.
  26.  
  27. Install 2 new O-rings to the cylinder block and oil pan No. 1.

    Click image to see an enlarged view

    Fig. Correct installation of the timing chain cover and water pump bolts and nuts-1.5L hybrid engine

  28.  
  29. Install the timing chain cover, new O-ring and water pump with the 16 bolts and 3 nuts. Uniformly tighten the bolts and nut in several passes to the following torque values:
    NOTE
    Pay attention not to wrap the chain and slipper over the chain cover seal line. After installing the chain cover, must install the mounting bracket and water pump within 15 minutes.



    Bolt A, 0.787 inch (20mm)-8 ft. lbs. (11 Nm)
     
    Bolt B, 1.181 inch (30mm)-18 ft. lbs. (24 Nm)
     
    Bolt C, 1.378 inch (35mm)-8 ft. lbs. (11 Nm)
     
    Bolt D, 0.787 inch (20mm)-18 ft. lbs. (24 Nm)
     
    Bolt E, 1.378 inch (35mm)-8 ft. lbs. (11 Nm)
     
    Nut F-18 ft. lbs. (24 Nm)
     
    Nut G-8 ft. lbs. (11 Nm)
     

  30.  
  31. Apply seal packing to threads of the engine mounting bracket mounting bolt, but do not apply seal packing to 2 or 3 threads of the bolt end.
  32.  
  33. Install the right mounting bracket with the 4 bolts and tighten to 41 ft. lbs. (55 Nm).
  34.  
  35. Install the crankshaft position sensor and tighten the bolt at the sensor to 66 inch lbs. (7.5 Nm), and the other bolts to 8 ft. lbs. (11 Nm).
  36.  
  37. Install the oil control valve and tighten to 66 inch lbs. (7.5 Nm).
  38.  
  39. Install the crankshaft pulley as follows:


    1. Clean the crankshaft pulley inside.
    2.  
    3. Install the pin to the crankshaft.
    4.  
    5. Align the hole in the crank pulley with the pin position and install the crank pulley.
    6.  
    7. Using SST 09213-70011 and 09330-00021, install the pulley bolt and tighten to 94 ft. lbs. (128 Nm).

      Click image to see an enlarged view

      Fig. Apply seal packing to 2 locations as shown-1.5L hybrid engine

    8.  

  40.  
  41. Remove any old packing (FIPG) material and apply seal packing to 2 locations as shown in the illustration.
  42.  
  43. Install the gasket to the cylinder head cover.
    NOTE
    Part must be assembled within 3 minutes of seal packing application. Otherwise the material must be remove and reapplied.

  44.  
  45. Install the cylinder head cover and cable bracket with the 7 bolts, 2 seal washers and 2 nuts. Uniformly tighten the bolts and nuts, in the several passes, in the sequence to 7 ft. lbs. (10 Nm).
  46.  
  47. Connect the 2 PCV hoses to the cylinder head cover.
  48.  
  49. Connect the engine wire to cylinder head cover.
  50.  
  51. Install the ignition coils.
  52.  
  53. Install the RH engine mounting insulator with the 5 bolts and 2 nuts.
  54.  
  55. Install VSV to right engine mounting insulator
  56.  
  57. Install the drive belt.
  58.  
  59. Install the engine coolant reservoir tank.
  60.  
  61. Install the air inlet.
  62.  
  63. Connect the Camshaft timing oil control valve connector.
  64.  
  65. Connect the water temperature sensor connector.
  66.  
  67. Connect the camshaft position sensor connector.
  68.  
  69. Connect the 2 VSV connectors.
  70.  
  71. Connect the 4 injector connectors.
  72.  
  73. Connect the 4 ignition connectors.
  74.  
  75. Install the air cleaner assembly.
  76.  
  77. Install brake fluid reservoir tank.
  78.  
  79. Install the outer front cowl top panel assembly.
  80.  
  81. Fill the engine with coolant.
  82.  
  83. Install the engine under covers.
  84.  
  85. Connect the negative battery cable and HV battery service plug.
  86.  
  87. Road test the vehicle and check for abnormal noises, shock slippage, correct shift points and smooth operation.
  88.  
  89. Recheck the engine and transaxle fluids.
  90.  

 
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