INSTALLATION Toyota Prius C I

INSTALLATION

HINT

Perform "Inspection After Repairs" after replacing the camshaft timing gear assembly, camshaft or No. 2 camshaft. Refer to INITIALIZATION .

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1. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY HINT: Perform "Inspection After Repairs" after replacing the camshaft timing gear assembly. Refer to «INITIALIZATION»(/toyota/prius-c/i-2011-2015/remont/testing-diagnostics/#engine-control-system-diagnostics-introduction) . Put the camshaft timing gear assembly and camshaft together with the straight pin and key groove misaligned as shown in the illustration. TEXT IN ILLUSTRATION *1 Straight Pin *a Key Groove Turn the camshaft timing gear assembly as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove. TEXT IN ILLUSTRATION *a View A *b Straight Pin *c Key Groove NOTE: Be sure not to turn the camshaft timing gear assembly to the retard direction (clockwise). Check that there is no clearance between the camshaft timing gear assembly and camshaft flange. TEXT IN ILLUSTRATION *a INCORRECT *b CORRECT *c Flange Tighten the bolt with the camshaft timing gear assembly secured in place. Torque: 64 N*m (652 kgf*cm, 47 ft.*lbf) NOTE: Do not lock the camshaft timing gear assembly when tightening the bolt. Release the lock pin of the camshaft timing gear assembly first, and tighten the bolt when the lock pin is locked in the most retarded position. Tightening the bolts with the lock pin locked could cause breakage of the lock pin. Check that the camshaft timing gear assembly can move to the retard direction (clockwise) and is locked in the most retarded position. TEXT IN ILLUSTRATION *a Lock
2. INSTALL CAMSHAFT HINT: Perform "Inspection After Repairs" after replacing the camshaft. Refer to «INITIALIZATION»(/toyota/prius-c/i-2011-2015/remont/testing-diagnostics/#engine-control-system-diagnostics-introduction) . Apply a light coat of engine oil to the camshaft journals and cylinder head sub-assembly journals. Install the chain sub-assembly onto the camshaft timing gear assembly with the paint mark on the chain sub-assembly aligned with the timing mark on the camshaft timing gear assembly as shown in the illustration. TEXT IN ILLUSTRATION *a Paint Mark *b Timing Mark Examine the front marks and numbers, and tighten the 4 No. 2 camshaft bearing caps with the 8 bolts in the sequence shown in the illustration. Torque: 13 N*m (129 kgf*cm, 9 ft.*lbf) NOTE: Tighten each bolt uniformly, keeping the camshaft level.
3. INSTALL NO. 2 CAMSHAFT HINT: Perform "Inspection After Repairs" after replacing the No. 2 camshaft. Refer to «INITIALIZATION»(/toyota/prius-c/i-2011-2015/remont/testing-diagnostics/#engine-control-system-diagnostics-introduction) . Apply a light coat of engine oil to the No. 2 camshaft journals and cylinder head sub-assembly journals. Put the camshaft timing gear or sprocket on the cylinder head sub-assembly with the paint mark on the chain sub-assembly aligned with the timing mark on the camshaft timing gear or sprocket. TEXT IN ILLUSTRATION *a Paint Mark *b Timing Mark (Rectangle) *c Mark (Circle) HINT: There are 3 marks on the camshaft timing gear or sprocket. Make sure to align the mark plate with the timing mark (rectangle). While holding the No. 2 camshaft by hand, temporarily install the No. 2 camshaft to the camshaft timing gear or sprocket using the bolt. Examine the front marks and numbers, and tighten the No. 1 camshaft bearing cap and No. 2 camshaft bearing caps with the 11 bolts in the sequence shown in the illustration. TEXT IN ILLUSTRATION *1 No. 1 Camshaft Bearing Cap *2 No. 2 Camshaft Bearing Cap No. 2 camshaft bearing cap Torque: 13 N*m (129 kgf*cm, 9 ft.*lbf) No. 1 camshaft bearing cap Torque: 23 N*m (234 kgf*cm, 17 ft.*lbf) NOTE: Tighten each bolt uniformly, keeping the No. 2 camshaft level. Using a 14 mm union nut wrench, tighten the bolts onto the camshaft timing gear or sprocket while holding the hexagonal portion of the No. 2 camshaft. Torque: 64 N*m (652 kgf*cm, 47 ft.*lbf) NOTE: Use the torque value compensation formula to calculate the torque value for use when a torque wrench is combined with a tool such as a union nut wrench. Refer to «PRECAUTION»(/toyota/prius-c/i-2011-2015/remont/hoistjack/#introduction) . Remove the hexagon wrench from the No. 1 chain tensioner assembly. Turn the crankshaft damper until its notch and timing mark "0" of the timing chain cover are aligned. TEXT IN ILLUSTRATION *a Timing Mark *b Timing Notch *c Timing Mark (Rectangle) *d Mark (Circle) *e Paint Mark HINT: There are 3 marks on the camshaft timing gear or sprocket. Make sure that the timing mark (rectangle) is at the top. Check that all the pairs of timing marks are aligned.
4. INSTALL SCREW PLUG . Refer to «INSTALLATION - Step 3»(/toyota/prius-c/i-2011-2015/remont/lubrication-system/#lubrication-system-service-information)
5. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Install a new gasket to the cylinder head cover sub-assembly. Apply seal packing to the 2 locations shown in the illustration. TEXT IN ILLUSTRATION Apply Seal Packing Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTE: Remove any oil from the contact surface. Install the cylinder head cover within 3 minutes of applying seal packing. Do not start the engine for at least 2 hours after installation. Temporarily install the cylinder head cover sub-assembly with the 9 bolts, 2 nuts and 2 new seal washers. TEXT IN ILLUSTRATION *1 Seal Washer Using several steps, uniformly tighten the bolts and nuts in the sequence shown in the illustration. Torque: 13 N*m (132 kgf*cm, 10 ft.*lbf) Connect the No. 1 ventilation hose and No. 2 ventilation hose.
6. CONNECT ENGINE WIRE Install the engine wire with the 3 bolts. Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf) Connect the wire harness clamp. Connect the 4 injector connectors.
7. INSTALL IGNITION COIL ASSEMBLY . Refer to «INSTALLATION - Step 2»(/toyota/prius-c/i-2011-2015/remont/engine-control-systems/#engine-control-system-service-information)
8. INSTALL EGR COOLER ASSEMBLY Refer to «INSTALLATION»(/toyota/prius-c/i-2011-2015/remont/auxiliary-emission-control-systems/#emission-control-system-service-information)

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1. REMOVE TIMING CHAIN COVER Refer to «REMOVAL»(/toyota/prius-c/i-2011-2015/remont/lubrication-system/#lubrication-system-service-information)
2. REMOVE INTAKE MANIFOLD STAY . Refer to «REMOVAL - Step 5»(/toyota/prius-c/i-2011-2015/remont/exhaust/#intake-system-exhaust-system-service-information)
3. REMOVE INTAKE MANIFOLD . Refer to «REMOVAL - Step 6»(/toyota/prius-c/i-2011-2015/remont/exhaust/#intake-system-exhaust-system-service-information)
4. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR . Refer to «REMOVAL - Step 4»(/toyota/prius-c/i-2011-2015/remont/exhaust/#intake-system-exhaust-system-service-information)
5. REMOVE MANIFOLD SUPPORT BRACKET . Refer to «REMOVAL - Step 5»(/toyota/prius-c/i-2011-2015/remont/exhaust/#intake-system-exhaust-system-service-information)
6. REMOVE EXHAUST MANIFOLD . Refer to «REMOVAL - Step 7»(/toyota/prius-c/i-2011-2015/remont/exhaust/#intake-system-exhaust-system-service-information)
7. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY Turn the stopper plate of the No. 1 chain tensioner assembly clockwise and push in the plunger with the lock released. TEXT IN ILLUSTRATION *1 Hexagon Wrench *2 Plunger *3 Stopper Plate Turn the stopper plate of the No. 1 chain tensioner assembly counterclockwise and insert a hexagon wrench into the hole in the stopper plate to lock with the plunger pushed in. Remove the 2 bolts and No. 1 chain tensioner assembly. NOTE: Do not rotate the crankshaft with the No. 1 chain tensioner removed.
8. REMOVE CHAIN TENSIONER SLIPPER Remove the chain tensioner slipper.
9. REMOVE NO. 1 CHAIN VIBRATION DAMPER Remove the 2 bolts and No. 1 chain vibration damper.
10. REMOVE CHAIN SUB-ASSEMBLY Remove the chain sub-assembly. NOTE: When rotating the camshaft with the chain sub-assembly removed, rotate the crankshaft counterclockwise 40° from TDC and align the oil jet hole with the paint mark to prevent the pistons from coming into contact with the valves.
11. REMOVE CAMSHAFT Using several steps, uniformly loosen and remove the 19 bolts in the sequence shown in the illustration, then remove the No. 1 camshaft bearing cap and 8 No. 2 camshaft bearing caps. NOTE: Uniformly loosen the bolts while keeping the camshaft level. Remove the camshaft and No. 2 camshaft.
12. REMOVE CYLINDER HEAD SUB-ASSEMBLY Using several steps, uniformly loosen and remove the 10 cylinder head bolts and 10 washers with an 8 mm bi-hexagon wrench in the sequence shown in the illustration. NOTE: When removing the cylinder head bolt, do not drop the washer into the cylinder head sub-assembly. Removing the bolts in the wrong order may cause damage to the cylinder head sub-assembly. Remove the cylinder head sub-assembly.
13. REMOVE CYLINDER HEAD GASKET Remove the cylinder head gasket from the cylinder block.

HINT

Perform "Inspection After Repairs" after replacing the cylinder head sub-assembly. Refer to INITIALIZATION .

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1. INSPECT CYLINDER HEAD SET BOLT See step 7
2. INSTALL CYLINDER HEAD GASKET Apply seal packing to a new cylinder head gasket as shown in the illustration. TEXT IN ILLUSTRATION *1 Cylinder Head Gasket *a Apply Seal Packing To The Inner Corners *b 4.5 to 5.5 mm (0.177 to 0.217 in.) Seal Packing Black Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTE: Install the cylinder head sub-assembly within 3 minutes and tighten the cylinder head bolts within 15 minutes after applying seal packing. Place the cylinder head gasket on the cylinder block with the Lot No. facing upward. TEXT IN ILLUSTRATION *a Lot Number NOTE: Remove any oil from the contact surface. Be careful of the installation direction.
3. INSTALL CYLINDER HEAD SUB-ASSEMBLY HINT: Perform "Inspection After Repairs" after replacing the cylinder head sub-assembly. Refer to «INITIALIZATION»(/toyota/prius-c/i-2011-2015/remont/testing-diagnostics/#engine-control-system-diagnostics-introduction) . The cylinder head bolts are tightened in 2 progressive steps. Place the cylinder head sub-assembly on the cylinder block. NOTE: Ensure that no oil is on the mounting surface of the cylinder head sub-assembly. Place the cylinder head sub-assembly gently in order not to damage the cylinder head gasket. Apply a light coat of engine oil to the threads and under the heads of the 10 cylinder head bolts. NOTE: Ensure that no engine oil drips from any of the cylinder head bolts. Step 1: Using several steps, uniformly install and tighten the 10 cylinder head bolts and 10 washers with an 8 mm bi-hexagon wrench in the order shown in the illustration. Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf) Step 2: Mark each cylinder head bolt head with paint as shown in the illustration. TEXT IN ILLUSTRATION *a Paint Mark Engine Front Further tighten the cylinder head bolts 90°, and then an additional 90° as shown in the illustration. Check that the paint mark is now at a 180° angle to the front. After tightening the cylinder head bolts, wipe off the seal packing material that seeped out from the contact surface between the cylinder head sub-assembly and cylinder block.
4. INSTALL CAMSHAFT Apply a light coat of engine oil to the camshaft and cylinder head sub-assembly journals. Place the camshaft and No. 2 camshaft on the cylinder head sub-assembly with the timing mark on the camshaft timing gear assembly and camshaft timing sprocket facing upward. TEXT IN ILLUSTRATION *a Timing Mark *b Timing Mark (Rectangle) *c Mark (Circle) HINT: There are 3 marks on the camshaft timing sprocket. Make sure that the timing mark (rectangle) is at the top. Check the front marks and numbers on the No. 1 camshaft bearing cap and 8 No. 2 camshaft bearing caps, then temporarily install them with the 19 bolts. TEXT IN ILLUSTRATION *1 No. 1 Camshaft Bearing Cap *2 No. 2 Camshaft Bearing Cap Uniformly tighten the 19 bolts in the sequence shown in the illustration. No. 2 camshaft bearing cap Torque: 13 N*m (129 kgf*cm, 9 ft.*lbf) No. 1 camshaft bearing cap Torque: 23 N*m (234 kgf*cm, 17 ft.*lbf) NOTE: Uniformly tighten the bolts while keeping the camshaft level.
5. INSTALL CHAIN SUB-ASSEMBLY Set the crankshaft in the position shown in the illustration. TEXT IN ILLUSTRATION *a Timing Mark HINT: The crankshaft will be set to 90° ATDC and the timing mark will be at the location shown in the illustration. Set the camshaft timing gear assembly and camshaft timing sprocket in the positions shown in the illustration. TEXT IN ILLUSTRATION *a Timing Mark *b Timing Mark (Rectangle) *c Mark (Circle) HINT: There are 3 marks on the camshaft timing sprocket. Make sure to set the timing mark (rectangle) to 10° as shown in the illustration. Make sure to set the camshaft timing gear assembly to 10° as shown in the illustration. This is the location of the camshafts when the crankshaft is 20° ATDC. Set the crankshaft in the position shown in the illustration. TEXT IN ILLUSTRATION *a Timing Mark HINT: The crankshaft will be set to 20° ATDC and the timing mark will be at the location shown in the illustration. Install the No. 1 chain vibration damper with the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) Align the timing marks of the camshaft and crankshaft with the mark plates of the timing chain sub-assembly and install the timing chain sub-assembly. TEXT IN ILLUSTRATION *a Timing Mark *b Timing Mark (Rectangle) *c Mark (Circle) *d Orange Mark Plate *e Yellow Mark Plate HINT: To prevent the No. 2 camshaft from springing back, turn it using a wrench and set it at the mark on the chain. There are 3 marks on the camshaft timing sprocket. Make sure to align the mark plate with the timing mark (rectangle). Install the chain tensioner slipper. Install the No. 1 chain tensioner assembly with the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) Remove the hexagon wrench from the No. 1 chain tensioner assembly. Turn the crankshaft approximately 20° counterclockwise to set it to TDC. Make sure that the timing marks and mark plates are correctly positioned. TEXT IN ILLUSTRATION *a Timing Mark *b Timing Mark (Rectangle) *c Mark (Circle) *d Orange Mark Plate *e Yellow Mark Plate HINT: There are 3 marks on the camshaft timing sprocket. Make sure that the timing mark (rectangle) is at the top.
6. INSTALL EXHAUST MANIFOLD . Refer to «INSTALLATION - Step 3»(/toyota/prius-c/i-2011-2015/remont/exhaust/#intake-system-exhaust-system-service-information)
7. INSTALL MANIFOLD SUPPORT BRACKET . Refer to «INSTALLATION - Step 5»(/toyota/prius-c/i-2011-2015/remont/exhaust/#intake-system-exhaust-system-service-information)
8. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR . Refer to «INSTALLATION - Step 6»(/toyota/prius-c/i-2011-2015/remont/exhaust/#intake-system-exhaust-system-service-information)
9. INSTALL INTAKE MANIFOLD . Refer to «INSTALLATION - Step 1»(/toyota/prius-c/i-2011-2015/remont/exhaust/#intake-system-exhaust-system-service-information)
10. INSTALL INTAKE MANIFOLD STAY . Refer to «INSTALLATION - Step 2»(/toyota/prius-c/i-2011-2015/remont/exhaust/#intake-system-exhaust-system-service-information)
11. INSTALL TIMING CHAIN COVER Refer to «INSTALLATION»(/toyota/prius-c/i-2011-2015/remont/lubrication-system/#lubrication-system-service-information)

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1. REMOVE FRONT WHEEL RH
2. REMOVE ENGINE UNDER COVER RH
3. SEPARATE NO. 2 ENGINE ROOM RELAY BLOCK AND NO. 2 JUNCTION BLOCK ASSEMBLY Remove the bolt and 2 nuts, and separate the No. 2 engine room relay block and No. 2 junction block assembly.
4. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH Place a jack underneath the engine, then put a wooden block on the jack. TEXT IN ILLUSTRATION Jack Position NOTE: To prevent the No. 2 oil pan from deforming, do not place any attachments onto the No. 2 oil pan. Remove the 4 bolts, 2 nuts and engine mounting insulator sub-assembly RH.
5. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY Using SST, hold the crankshaft damper sub-assembly in place and loosen the bolt. TEXT IN ILLUSTRATION *a Hold Turn SST: 09213-58012 91111-50845 SST: 09330-00021 NOTE: When installing SST, be careful that the bolt which holds SST does not interfere with the timing chain cover. Using SST, remove the crankshaft damper sub-assembly and bolt. TEXT IN ILLUSTRATION *a Hold Turn SST: 09950-50013 09951-05010 09952-05010 09953-05020 09954-05021 HINT: Apply a lubricant to the threads and end of SST.
6. REMOVE OIL PUMP SEAL Using a knife, cut off the lip of the oil pump seal. TEXT IN ILLUSTRATION *1 Protective Tape *a Cut Position Using a screwdriver with its tip wrapped with tape, pry out the oil seal. NOTE: Do not damage the surface of the oil seal press fit hole or the crankshaft. HINT: Wrap the screwdriver tip with protective tape before use. After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper.

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1. INSTALL OIL PUMP SEAL Apply MP grease to the lip of a new oil pump seal. NOTE: Keep the lip free from foreign matter. Using SST and a hammer, tap in the oil pump seal until its surface is flush with the front oil pump seal retainer edge. SST: 09223-22010 Tap in depth 0 to 1.0 mm from the edge of the timing chain cover. NOTE: Do not tap the oil pump seal at an angle. Wipe off extra grease from the crankshaft.
2. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY Align the hole of the crankshaft damper sub-assembly with the straight pin, then install the crankshaft damper sub-assembly. Using SST, hold the crankshaft damper sub-assembly in place and tighten the bolt. TEXT IN ILLUSTRATION *a Hold Turn SST: 09213-58012 91111-50845 SST: 09330-00021 Torque: 128 N*m (1305 kgf*cm, 94 ft.*lbf) NOTE: When installing SST, be careful that the bolt which holds SST does not interfere with the timing chain cover.
3. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH Temporarily install the engine mounting insulator sub-assembly RH with the 4 bolts and 2 nuts. Tighten the 3 bolts (A) in the sequence shown in the illustration. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) Tighten the bolt (B) and 2 nuts. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf)
4. INSTALL NO. 2 ENGINE ROOM RELAY BLOCK AND NO. 2 JUNCTION BLOCK ASSEMBLY Install the No. 2 engine room relay block and No. 2 junction block assembly with the 2 nuts and bolt. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
5. INSPECT FOR OIL LEAK
6. INSTALL ENGINE UNDER COVER RH
7. INSTALL FRONT WHEEL RH Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf)

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1. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY Refer to «REMOVAL»(/toyota/prius-c/i-2011-2015/remont/automatic-trans/#hybrid-transaxle-service-information) NOTE: 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.
2. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY Using SST, hold the crankshaft damper sub-assembly. SST: 09213-58012 91111-50845 SST: 09330-00021 Remove the 6 bolts and transmission input damper assembly from the flywheel sub-assembly.
3. REMOVE FLYWHEEL SUB-ASSEMBLY Using SST, hold the crankshaft damper sub-assembly. SST: 09213-58012 91111-50845 SST: 09330-00021 Remove the 6 bolts and flywheel sub-assembly.
4. REMOVE REAR ENGINE OIL SEAL Using a knife, cut off the lip of the rear engine oil seal. TEXT IN ILLUSTRATION *1 Protective Tape *a Cut Position Using a screwdriver with its tip wrapped with tape, pry out the rear engine oil seal. NOTE: Do not damage the surface of the oil seal press fit hole or the crankshaft. HINT: Wrap the screwdriver tip with protective tape before use. After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper.

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1. INSTALL REAR ENGINE OIL SEAL Apply MP grease to the lip of a new rear engine oil seal. NOTE: Keep the lip free from foreign matter. Using SST and a hammer, tap in the rear engine oil seal until its surface is flush with the rear engine oil seal retainer edge. SST: 09223-56010 Tap in depth 0 to 1.0 mm from the edge of the timing chain cover. NOTE: Do not tap the rear engine oil seal at an angle. Wipe off extra grease from the crankshaft.
2. INSTALL FLYWHEEL SUB-ASSEMBLY Using SST, hold the crankshaft damper sub-assembly. SST: 09213-58012 91111-50845 SST: 09330-00021 NOTE: When installing SST, be careful that the bolt which holds SST does not interfere with the timing chain cover. Apply adhesive to the 2 or 3 end threads of 6 new bolts. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Temporarily install the flywheel sub-assembly with the 6 new bolts. Tighten the 6 bolts in the sequence shown in the illustration. Torque: 83 N*m (846 kgf*cm, 61 ft.*lbf)
3. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY Using SST, hold the crankshaft damper sub-assembly. SST: 09213-58012 91111-50845 SST: 09330-00021 NOTE: When installing SST, be careful that the bolt which holds SST does not interfere with the timing chain cover. Temporarily install the transmission input damper assembly with 6 new bolts. Tighten the 6 bolts in the sequence shown in the illustration. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) NOTE: Remove any oil from the transmission input damper assembly and flywheel sub-assembly. Make sure that the front-rear direction of the transmission input damper assembly is correct when installing it.
4. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY Refer to «INSTALLATION»(/toyota/prius-c/i-2011-2015/remont/automatic-trans/#hybrid-transaxle-service-information) NOTE: 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.

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