Engine Mechanical (service Information) Toyota Prius C I

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1. INSPECT COOLANT (for Engine) Refer to «ON-VEHICLE INSPECTION»(/toyota/prius-c/i-2011-2015/remont/cooling-fan/#engine-cooling-system-inspection__on-vehicle-inspection)
2. INSPECT ENGINE OIL Refer to «ON-VEHICLE INSPECTION»(/toyota/prius-c/i-2011-2015/remont/lubrication-system/#lubrication-system-inspection)
3. INSPECT AUXILIARY BATTERY Refer to «ON-VEHICLE INSPECTION»(/toyota/prius-c/i-2011-2015/remont/charging-system/#charging-system-inspection)
4. INSPECT SPARK PLUG Refer to «ON-VEHICLE INSPECTION»(/toyota/prius-c/i-2011-2015/remont/ignition-system/#ignition-system-inspection)
5. INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY Remove the air cleaner cap. Remove the air cleaner filter element. Visually check that the air cleaner filter element is not excessively damaged or oily. If necessary, replace the air cleaner filter element. Install the air cleaner filter element. Install the air cleaner cap.
6. INSPECT IGNITION TIMING Put the engine in inspection mode (maintenance mode). Refer to «INSPECTION MODE PROCEDURE»(/toyota/prius-c/i-2011-2015/remont/hoistjack/#introduction) . Warm up and stop the engine. When using the Techstream: Connect the Techstream to the DLC3. Put the engine in inspection mode (maintenance mode). Refer to «INSPECTION MODE PROCEDURE»(/toyota/prius-c/i-2011-2015/remont/hoistjack/#introduction) . Start the engine. Enter the following menus: Powertrain / Engine and ECT / Data List / IGN Advance. Standard ignition timing 12 to 16 degrees BTDC NOTE: Check the ignition timing with the cooling fan off. Turn off all electrical systems and the A/C. When checking the ignition timing, the transaxle should be in park. HINT: Refer to the Techstream operator's manual for further details. Check that the ignition timing advances immediately when the engine speed is increased. Enter the following menus: Powertrain / Engine and ECT / Active Test / Connect the TC and TE1 / ON. Monitor IGN Advance of the Data List. Standard ignition timing 8 to 12 degrees BTDC NOTE: Check the ignition timing with the cooling fan off. Turn off all electrical systems and the A/C. When checking the ignition timing, the transaxle should be in park. HINT: Refer to the Techstream operator's manual for further details. Enter the following menus: Connect the TC and TE1 / OFF. Turn the ignition switch off. Turn the Techstream off. Disconnect the Techstream from the DLC3. When not using the Techstream: Connect the clip of a timing light to the ignition coil wire for No. 1 cylinder. NOTE: Use a timing light that detects the primary signal. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3. TEXT IN ILLUSTRATION *a DLC3 SST: 09843-18040 NOTE: Confirm the terminals before connecting them. Connecting the wrong terminals may result in damage to electrical components. Put the engine in inspection mode (maintenance mode). Refer to «INSPECTION MODE PROCEDURE»(/toyota/prius-c/i-2011-2015/remont/hoistjack/#introduction) . Start the engine. Inspect the ignition timing at idle. Standard ignition timing 8 to 12 degrees BTDC NOTE: Check the ignition timing with the cooling fan off. Turn off all electrical systems and the A/C. When checking the ignition timing, the transaxle should be in park. Disconnect terminals 13 (TC) and 4 (CG) of the DLC3. Inspect the ignition timing at idle. Standard ignition timing 12 to 16 degrees BTDC NOTE: Check the ignition timing with the cooling fan off. Turn off all electrical systems and the A/C. When checking the ignition timing, the transaxle should be in park. Confirm that the ignition timing advances when the engine rpm is increased. Remove the timing light.
7. INSPECT ENGINE IDLE SPEED Put the engine in inspection mode (maintenance mode). Refer to «INSPECTION MODE PROCEDURE»(/toyota/prius-c/i-2011-2015/remont/hoistjack/#introduction) . Warm up and stop the engine. When using the Techstream: Connect the Techstream to the DLC3. Put the engine in inspection mode (maintenance mode). Refer to «INSPECTION MODE PROCEDURE»(/toyota/prius-c/i-2011-2015/remont/hoistjack/#introduction) . Start the engine. Enter the following menus: Powertrain / Engine and ECT / Data List / Engine Speed. HINT: Refer to the Techstream operator's manual for further details. Inspect the engine idle speed. Standard idle speed 950 to 1050 rpm NOTE: Turn all electrical systems and the A/C off. Inspect the idle speed with the cooling fan off. When checking the idle speed, the transaxle should be in park. Turn the ignition switch off. Turn the Techstream off. Disconnect the Techstream from the DLC3. When not using the Techstream: Using SST, connect a tachometer tester probe to terminal 9 (TAC) of the DLC3. TEXT IN ILLUSTRATION *a DLC3 SST: 09843-18030 Put the engine in inspection mode (maintenance mode). Refer to «INSPECTION MODE PROCEDURE»(/toyota/prius-c/i-2011-2015/remont/hoistjack/#introduction) . Inspect the engine idle speed. Standard idle speed 950 to 1050 rpm NOTE: Turn all electrical systems and the A/C off. Inspect the idle speed with the cooling fan off. When checking the idle speed, the transaxle should be in park. Disconnect terminal 9 (TAC) of the DLC3.
8. INSPECT COMPRESSION Put the engine in inspection mode (maintenance mode). Refer to «INSPECTION MODE PROCEDURE»(/toyota/prius-c/i-2011-2015/remont/hoistjack/#introduction) . Warm up and stop the engine. Remove the 4 spark plugs. Refer to «REMOVAL»(/toyota/prius-c/i-2011-2015/remont/engine-control-systems/#engine-control-system-service-information) . NOTE: If the ignition coil assembly connector is disconnected because a DTC is detected in inspection, always reconnect it. Insert a compression gauge into the spark plug hole. Connect the Techstream to the DLC3. Turn the ignition switch to ON (IG). Turn the Techstream on. NOTE: Check the HV battery voltage in the data list to ensure that the battery is fully charged. Enter the following menus: Powertrain / Hybrid Control / Active Test / Compression Test / ON. Depress and hold the brake pedal, and turn the ignition switch to ON (READY). Standard compression pressure 871 kPa (8.9 kgf/cm 2 , 126 psi) Minimum pressure 661 kPa (6.7 kgf/cm 2 , 96 psi) Pressure difference between each cylinder 100 kPa (1.0 kgf/cm 2 , 15 psi) NOTE: Inspect the other cylinders in the same way. Measure the compression as quickly as possible. HINT: If the cylinder compression is low, pour a small amount of engine oil into the cylinder through the spark plug hole, then inspect it again. If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged. If the pressure stays low, a valve may be stuck or seated improperly, or there may be leaks from the gasket. Install the 4 spark plugs. Refer to «INSTALLATION»(/toyota/prius-c/i-2011-2015/remont/engine-control-systems/#engine-control-system-service-information) . Clear the DTCs. Refer to «DTC CHECK / CLEAR»(/toyota/prius-c/i-2011-2015/remont/testing-diagnostics/#engine-control-system-diagnostics-introduction__dtc-check-clear) . HINT: Reinstall the sensors, connectors, etc. and restore the previous vehicle conditions before rechecking for DTCs.
9. INSPECT CO/HC HINT: This check determines whether or not the idle CO / HC complies with regulations. Put the engine in inspection mode (maintenance mode). Refer to «INSPECTION MODE PROCEDURE»(/toyota/prius-c/i-2011-2015/remont/hoistjack/#introduction) . Start the engine. Run the engine at 2500 rpm for approximately 180 seconds. Insert a CO/HC meter testing probe at least 40 cm (1.31 ft.) into the tailpipe while idling. Check the CO/HC concentration while idling and when the engine is running at 2500 rpm. HINT: When doing a 2 mode (with the engine idling/ running at 2500 rpm) test, the measurement procedures are determined by applicable local regulations. If the CO/HC concentration does not comply with the regulations, troubleshoot in the order given below. Check the DTCs. Refer to «DTC CHECK / CLEAR»(/toyota/prius-c/i-2011-2015/remont/testing-diagnostics/#engine-control-system-diagnostics-introduction__dtc-check-clear) . See the table below for possible causes, then inspect the applicable parts and repair them if necessary. CO HC Problem Possible Cause Normal High Rough idle Faulty ignition: Incorrect timing Fouled, shorted or improperly gapped plugs Incorrect valve clearance Leaks from intake and exhaust valves Leaks from cylinders Faulty EGR Low High Rough idle (Fluctuating HC reading) Vacuum leaks: PCV hoses Intake manifold Throttle body Lean mixture causing misfire Faulty EGR High High Rough idle (Black smoke from exhaust) Restricted air cleaner filter element Plugged PCV valve Faulty EFI systems: Faulty pressure regulator Faulty engine coolant temperature sensor Faulty mass air flow meter Faulty ECM Faulty injectors Throttle body Faulty EGR

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1. INSPECT VALVE CLEARANCE Check for noise and vibration Check for valve noise or a rough idle. Judge whether the valve clearance needs to be adjusted. HINT: If the valve noise is too loud or the idle is rough, inspect the valve clearance. Refer to «ADJUSTMENT»(/toyota/prius-c/i-2011-2015/remont/mechanical/#engine-mechanical-service-information) .

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1. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Refer to «REMOVAL»(/toyota/prius-c/i-2011-2015/remont/mechanical/#engine-mechanical-service-information__removal)
2. SET NO. 1 CYLINDER TO TDC / COMPRESSION 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 Check that the timing marks on both the camshaft timing gear or sprocket and the camshaft timing gear assembly are facing upward as shown in the illustration. HINT: If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above. There are 3 marks on the camshaft timing gear or sprocket. Make sure that the timing mark (rectangle) is at the top. Place paint marks on the chain sub-assembly in alignment with the timing marks on the camshaft timing gear assembly and camshaft timing gear or sprocket.
3. INSPECT VALVE CLEARANCE Check only the valves indicated. TEXT IN ILLUSTRATION *a No. 1 Cylinder TDC/Compression *b Intake Side *c Exhaust Side Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Standard Valve Clearance (Cold) Item Specified Condition Intake 0.15 to 0.25 mm (0.00591 to 0.00984 in.) Exhaust 0.25 to 0.35 mm (0.00984 to 0.0138 in.) HINT: Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifters. Turn the crankshaft 1 revolution (360°) and set the No. 4 cylinder to TDC/compression. Check only the valves indicated. TEXT IN ILLUSTRATION *a No. 4 Cylinder TDC/Compression *b Intake Side *c Exhaust Side Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Standard Valve Clearance (Cold) Item Specified Condition Intake 0.15 to 0.25 mm (0.00591 to 0.00984 in.) Exhaust 0.25 to 0.35 mm (0.00984 to 0.0138 in.) HINT: Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifters.
4. ADJUST VALVE CLEARANCE Remove the camshaft. Refer to «REMOVAL»(/toyota/prius-c/i-2011-2015/remont/mechanical/#engine-mechanical-service-information__removal) . Remove the valve lifters. HINT: Arrange the valve lifters in the same order as removed. Using a micrometer, measure the thickness of the removed valve lifters. Calculate the thickness of a new valve lifter so that the valve clearance comes within the specified range. New Valve Lifter Thickness Item Specification Intake A = B + (C - 0.20 mm (0.00787 in.)) Exhaust A = B + (C - 0.30 mm (0.0118 in.)) A New valve lifter thickness B Used valve lifter thickness C Measured valve clearance CALCULATION EXAMPLE (Intake): Measured intake valve clearance = 0.40 mm (0.0157 in.) (Measured - Specification = Excess clearance) 0.40 mm (0.0157 in.) - 0.20 mm (0.00787 in.) = 0.20 mm (0.00787 in.) Measured used valve lifter thickness = 5.250 mm (0.207 in.) New valve lifter thickness = 5.450 mm (0.21457 in.) (Excess clearance + Used valve lifter thickness = Ideal new valve lifter) 0.20 mm (0.00787 in.) + 5.250 mm (0.207 in.) = 5.450 mm (0.21457 in.) Closest new valve lifter = 5.460 mm (0.21496 in.) Select No. 42 valve lifter Select a new lifter with a thickness as close as possible to the calculated values. HINT: Lifters are available in 35 sizes in increments of 0.020 mm (0.000787 in.), from 5.060 to 5.740 mm (0.1992 to 0.2260 in.). Refer to the new valve lifter thickness table below. Valve lifter selection chart (intake). Valve lifter selection chart (intake) (continued). New lifter thickness Lifter No. Thickness Lifter No. Thickness Lifter No. Thickness 06 5.060 mm (0.1992 in.) 30 5.300 mm (0.2087 in.) 54 5.540 mm (0.2181 in.) 08 5.080 mm (0.2000 in.) 32 5.320 mm (0.2094 in.) 56 5.560 mm (0.2189 in.) 10 5.100 mm (0.2008 in.) 34 5.340 mm (0.2102 in.) 58 5.580 mm (0.2197 in.) 12 5.120 mm (0.2016 in.) 36 5.360 mm (0.2110 in.) 60 5.600 mm (0.2205 in.) 14 5.140 mm (0.2024 in.) 38 5.380 mm (0.2118 in.) 62 5.620 mm (0.2213 in.) 16 5.160 mm (0.2031 in.) 40 5.400 mm (0.2126 in.) 64 5.640 mm (0.2220 in.) 18 5.180 mm (0.2039 in.) 42 5.420 mm (0.2134 in.) 66 5.660 mm (0.2228 in.) 20 5.200 mm (0.2047 in.) 44 5.440 mm (0.2142 in.) 68 5.680 mm (0.2236 in.) 22 5.220 mm (0.2055 in.) 46 5.460 mm (0.2150 in.) 70 5.700 mm (0.2244 in.) 24 5.240 mm (0.2063 in.) 48 5.480 mm (0.2157 in.) 72 5.720 mm (0.2252 in.) 26 5.260 mm (0.2071 in.) 50 5.500 mm (0.2165 in.) 74 5.740 mm (0.2260 in.) 28 5.280 mm (0.2079 in.) 52 5.520 mm (0.2173 in.) - - Standard intake valve clearance (Cold) 0.17 to 0.23 mm (0.00669 to 0.00906 in.) EXAMPLE: A 5.250 mm (0.207 in.) valve lifter is installed, and the measured clearance is 0.400 mm (0.0157 in.). Replace the 5.250 mm (0.207 in.) valve lifter with a new No. 46 valve lifter. Valve lifter selection chart (exhaust). Valve selection chart (exhaust) (continued). New lifter thickness Lifter No. Thickness Lifter No. Thickness Lifter No. Thickness 06 5.060 mm (0.1992 in.) 30 5.300 mm (0.2087 in.) 54 5.540 mm (0.2181 in.) 08 5.080 mm (0.2000 in.) 32 5.320 mm (0.2094 in.) 56 5.560 mm (0.2189 in.) 10 5.100 mm (0.2008 in.) 34 5.340 mm (0.2102 in.) 58 5.580 mm (0.2197 in.) 12 5.120 mm (0.2016 in.) 36 5.360 mm (0.2110 in.) 60 5.600 mm (0.2205 in.) 14 5.140 mm (0.2024 in.) 38 5.380 mm (0.2118 in.) 62 5.620 mm (0.2213 in.) 16 5.160 mm (0.2031 in.) 40 5.400 mm (0.2126 in.) 64 5.640 mm (0.2220 in.) 18 5.180 mm (0.2039 in.) 42 5.420 mm (0.2134 in.) 66 5.660 mm (0.2228 in.) 20 5.200 mm (0.2047 in.) 44 5.440 mm (0.2142 in.) 68 5.680 mm (0.2236 in.) 22 5.220 mm (0.2055 in.) 46 5.460 mm (0.2150 in.) 70 5.700 mm (0.2244 in.) 24 5.240 mm (0.2063 in.) 48 5.480 mm (0.2157 in.) 72 5.720 mm (0.2252 in.) 26 5.260 mm (0.2071 in.) 50 5.500 mm (0.2165 in.) 74 5.740 mm (0.2260 in.) 28 5.280 mm (0.2079 in.) 52 5.520 mm (0.2173 in.) - - Standard exhaust valve clearance (Cold) 0.27 to 0.33 mm (0.0106 to 0.0130 in.) EXAMPLE: A 5.340 mm (0.210 in.) valve lifter is installed, and the measured clearance is 0.440 mm (0.0173 in.). Replace the 5.340 mm (0.210 in.) valve lifter with a new No. 48 valve lifter. Install the selected valve lifter. Install the camshaft. Refer to «INSTALLATION»(/toyota/prius-c/i-2011-2015/remont/mechanical/#engine-mechanical-service-information__installation) .
5. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Refer to «INSTALLATION»(/toyota/prius-c/i-2011-2015/remont/mechanical/#engine-mechanical-service-information__installation)

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1. REMOVE EGR COOLER ASSEMBLY Refer to «REMOVAL»(/toyota/prius-c/i-2011-2015/remont/auxiliary-emission-control-systems/#emission-control-system-service-information)
2. REMOVE IGNITION COIL ASSEMBLY . Refer to «REMOVAL - Step 1»(/toyota/prius-c/i-2011-2015/remont/engine-control-systems/#engine-control-system-service-information)
3. SEPARATE ENGINE WIRE Disconnect the 4 injector connectors. Disconnect the wire harness clamp. Remove the 3 bolts and separate the engine wire.
4. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Disconnect the No. 1 ventilation hose and No. 2 ventilation hose. Remove the 9 bolts, 2 seal washers, 2 nuts and cylinder head cover sub-assembly. Remove the gasket from the cylinder head cover sub-assembly.
5. SET NO. 1 CYLINDER TO TDC / COMPRESSION See step 2
6. REMOVE SCREW PLUG . Refer to «REMOVAL - Step 12»(/toyota/prius-c/i-2011-2015/remont/lubrication-system/#lubrication-system-service-information)
7. REMOVE NO. 2 CAMSHAFT Loosen the bolts on the camshaft timing gear or sprocket while holding the hexagonal portion of the No. 2 camshaft. TEXT IN ILLUSTRATION *a Hold Insert a screwdriver from the plug hole and turn the stopper plate of the No. 1 chain tensioner assembly clockwise to release the lock, and keep it as it is. TEXT IN ILLUSTRATION *1 Plunger *2 Stopper Plate *a Unlock HINT: The plunger of the No. 1 chain tensioner assembly is locked. If the stopper plate is locked firmly, slightly turn the hexagonal portion of the camshaft to the right and left. Slightly turn the hexagonal portion of the No. 2 camshaft clockwise so that the plunger of the No. 1 chain tensioner assembly is pushed by the chain sub-assembly. TEXT IN ILLUSTRATION *1 Plunger Insert a screwdriver from the plug hole and turn the stopper plate of the No. 1 chain tensioner assembly counterclockwise to the lock, and keep it as it is. Insert the hexagon wrench into the stopper plate hole. TEXT IN ILLUSTRATION *1 Hexagon Wrench *2 Plunger *3 Stopper Plate *a Lock HINT: Hold the hexagon wrench with tape so that the hexagon wrench does not come off. Using several steps, uniformly loosen and remove the 11 bolts in the sequence shown in the illustration. Then remove the No. 1 camshaft bearing cap and 4 No. 2 camshaft bearing caps. NOTE: Uniformly loosen the bolts while keeping the No. 2 camshaft level. Remove the bolt with the No. 2 camshaft lifted up. Remove the No. 2 camshaft and camshaft timing gear or sprocket.
8. REMOVE CAMSHAFT Loosen the bolts on the camshaft timing gear assembly while holding the hexagonal portion of the camshaft. TEXT IN ILLUSTRATION *a Hold Using several steps, uniformly loosen and remove the 8 bolts in the sequence shown in the illustration. Then remove the 4 No. 2 camshaft bearing caps. NOTE: Uniformly loosen the bolts while keeping the camshaft level. Hold the chain sub-assembly with one hand, and remove the camshaft. Tie the chain sub-assembly with a string or similar as shown in the illustration. NOTE: Be careful not to drop anything inside the timing chain cover.
9. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY Check the camshaft timing gear assembly lock. Clamp the camshaft in a vise, and make sure that the camshaft timing gear assembly does not rotate. Release the lock pin. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. TEXT IN ILLUSTRATION *a Retard Side Path *b Advance Side Path *c Open *d Close Rubber Piece Vinyl Tape HINT: 4 oil paths are provided in the groove. Plug 2 paths with rubber pieces. Prick a hole in the tape placed on the advance side path. Prick a hole in the tape placed on the retard side path, on the opposite side to that of the advance side path, as shown in the illustration. Apply approximately 150 kPa (1.5 kgf/cm2, 22 psi) of air pressure to the 2 paths (the advance side path and the retard side path). TEXT IN ILLUSTRATION *a Advance Side Path *b Retard Side Path HINT: Cover the paths with a piece of cloth when applying pressure to keep oil from spraying. Make sure that the camshaft timing sprocket turns in the retard direction when reducing the air pressure applied to the advance side path. TEXT IN ILLUSTRATION *a Advance Side Path *b Retard Side Path *c Decompress *d Hold Pressure HINT: The lock pin is released and the camshaft timing sprocket turns in the retard direction. When the camshaft timing sprocket moves to the most retarded position, release the air pressure from the advance side path, and then release the air pressure from the retard side path. NOTE: Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing sprocket may abruptly shift in the advance direction and break the lock pin or other parts.
10. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY Remove the bolt and camshaft timing gear assembly. TEXT IN ILLUSTRATION *a Do Not Remove NOTE: Be sure not to remove the other 4 bolts. When reusing the camshaft timing gear assembly, release the lock pin first, then install the camshaft timing gear assembly.

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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REMOVAL

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1. PRECAUTION WARNING: The vehicle has a hybrid system that operates at voltages up to 650 V. The hybrid system uses an HV battery that contains an electrolyte which is a strong alkali solution that includes potassium hydroxide. Be sure to follow the instructions in this service information to handle the system correctly. Failure to do so may result in serious injury or electrocution. Refer to «PRECAUTION»(/toyota/prius-c/i-2011-2015/remont/hoistjack/#introduction) . NOTE: After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to «PRECAUTION»(/toyota/prius-c/i-2011-2015/remont/hoistjack/#introduction) .
2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM . Refer to «REPLACEMENT - Step 1»(/toyota/prius-c/i-2011-2015/remont/automatic-hvac-system/#air-conditioning-system-service-information)
3. DISCHARGE FUEL SYSTEM PRESSURE Refer to «PRECAUTION»(/toyota/prius-c/i-2011-2015/remont/fuel-system/#fuel-system-inspection)
4. REMOVE SERVICE PLUG GRIP Refer to «REMOVAL»(/toyota/prius-c/i-2011-2015/remont/engine-control-systems/#hybrid-battery-control-system-service-information)
5. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL Refer to «REMOVAL»(/toyota/prius-c/i-2011-2015/remont/body-electrical/#12-volt-battery-service-information)
6. REMOVE ENGINE UNDER COVER LH
7. REMOVE ENGINE UNDER COVER RH
8. DRAIN ENGINE OIL . Refer to «REPLACEMENT - Step 1»(/toyota/prius-c/i-2011-2015/remont/lubrication-system/#lubrication-system-service-information)
9. DRAIN COOLANT (for Engine) . Refer to «REPLACEMENT - Step 1»(/toyota/prius-c/i-2011-2015/remont/cooling-fan/#engine-cooling-system-service-information)
10. DRAIN COOLANT (for Inverter) . Refer to «REPLACEMENT - Step 1»(/toyota/prius-c/i-2011-2015/remont/engine-control-systems/#hybrid-battery-control-system-service-information)
11. DRAIN HYBRID TRANSAXLE FLUID . Refer to «ADJUSTMENT - Step 1»(/toyota/prius-c/i-2011-2015/remont/automatic-trans/#hybrid-transaxle-service-information)
12. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Refer to «REMOVAL»(/toyota/prius-c/i-2011-2015/remont/wiperwasher-systems/#wiper-system-washer-system-service-information)
13. REMOVE INNER COWL TOP TO COWL BRACE . Refer to «REMOVAL - Step 4»(/toyota/prius-c/i-2011-2015/remont/mechanical-hydraulic/#brake-system-hydraulic-service-information)
14. REMOVE FRONT AIR SHUTTER SEAL . Refer to «REMOVAL - Step 5»(/toyota/prius-c/i-2011-2015/remont/mechanical-hydraulic/#brake-system-hydraulic-service-information)
15. REMOVE FRONT NO. 1 VENTILATOR SEAL . Refer to «REMOVAL - Step 6»(/toyota/prius-c/i-2011-2015/remont/mechanical-hydraulic/#brake-system-hydraulic-service-information)
16. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to «REMOVAL - Step 7»(/toyota/prius-c/i-2011-2015/remont/mechanical-hydraulic/#brake-system-hydraulic-service-information)
17. REMOVE INVERTER WITH CONVERTER ASSEMBLY Refer to «REMOVAL»(/toyota/prius-c/i-2011-2015/remont/engine-control-systems/#hybrid-battery-control-system-service-information__removal)
18. REMOVE AIR CLEANER CAP SUB-ASSEMBLY . Refer to «REMOVAL - Step 2»(/toyota/prius-c/i-2011-2015/remont/engine-control-systems/#engine-control-system-service-information)
19. REMOVE AIR CLEANER CASE SUB-ASSEMBLY . Refer to «REMOVAL - Step 2»(/toyota/prius-c/i-2011-2015/remont/auxiliary-emission-control-systems/#emission-control-system-service-information)
20. REMOVE INVERTER BRACKET ASSEMBLY WARNING: Wear insulated gloves. Remove the bolt and separate the motor cable protector. Disconnect the 2 wire harness clamps. Remove the 2 bolts and separate the inverter reservoir tank assembly. Remove the bolt and disconnect the earth wire. Remove the 4 bolts and inverter bracket assembly.
21. DISCONNECT NO. 1 RADIATOR HOSE Disconnect the No. 1 radiator hose from the engine assembly.
22. DISCONNECT NO. 2 RADIATOR HOSE Disconnect the No. 2 radiator hose from the engine assembly.
23. DISCONNECT HEATER WATER HOSE Disconnect the 2 heater water hoses from the engine assembly.
24. DISCONNECT FUEL VAPOR FEED HOSE ASSEMBLY Disconnect the fuel vapor feed hose assembly.
25. DISCONNECT FUEL TUBE SUB-ASSEMBLY . Refer to «REMOVAL - Step 10»(/toyota/prius-c/i-2011-2015/remont/fuel-system/#fuel-system-service-information)
26. DISCONNECT ENGINE WIRE Push the lock on the lever, then raise the lever, and disconnect the ECM connector. NOTE: If there is any foreign matter such as mud or water on a connector, clean the connector. Disconnect the 2 wire harness clamps. Disconnect the 2 connectors and wire harness clamp. Using a screwdriver, disengage the claw and disconnect the engine wire from the engine room relay block and junction block assembly. Disconnect the engine wire from the engine room main wire. Disconnect the wire harness clamp.
27. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY . Refer to «REMOVAL - Step 17»(/toyota/prius-c/i-2011-2015/remont/automatic-trans/#hybrid-transaxle-service-information)
28. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
29. SECURE STEERING WHEEL . Refer to «REMOVAL - Step 2»(/toyota/prius-c/i-2011-2015/remont/manual-power-steering/#steering-gear-linkage-service-information)
30. REMOVE COLUMN HOLE COVER SILENCER SHEET . Refer to «REMOVAL - Step 9»(/toyota/prius-c/i-2011-2015/remont/steering-column/#steering-column-service-information)
31. REMOVE STEERING SLIDING YOKE SUB-ASSEMBLY . Refer to «REMOVAL - Step 11»(/toyota/prius-c/i-2011-2015/remont/steering-column/#steering-column-service-information)
32. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY . Refer to «REMOVAL - Step 5»(/toyota/prius-c/i-2011-2015/remont/manual-power-steering/#steering-gear-linkage-service-information)
33. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE . Refer to «REMOVAL - Step 5»(/toyota/prius-c/i-2011-2015/remont/automatic-hvac-system/#air-conditioning-system-service-information)
34. DISCONNECT SUCTION HOSE SUB-ASSEMBLY . Refer to «REMOVAL - Step 6»(/toyota/prius-c/i-2011-2015/remont/automatic-hvac-system/#air-conditioning-system-service-information)
35. REMOVE COMPRESSOR WITH MOTOR ASSEMBLY . Refer to «REMOVAL - Step 7»(/toyota/prius-c/i-2011-2015/remont/automatic-hvac-system/#air-conditioning-system-service-information)
36. REMOVE FRONT EXHAUST PIPE ASSEMBLY . Refer to «REMOVAL - Step 2»(/toyota/prius-c/i-2011-2015/remont/exhaust/#intake-system-exhaust-system-service-information)
37. SEPARATE NO. 2 ENGINE ROOM RELAY BLOCK AND NO. 2 JUNCTION BLOCK ASSEMBLY See step 3
38. REMOVE FRONT DRIVE SHAFT ASSEMBLY Refer to «REMOVAL»(/toyota/prius-c/i-2011-2015/remont/axle-shafts/#drive-shaft-propeller-shaftfront-service-information__removal)
39. REMOVE FLYWHEEL HOUSING UNDER COVER Remove the flywheel housing under cover.
40. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE Set the engine lifter. TEXT IN ILLUSTRATION *1 No. 2 Oil Pan Sub-assembly *2 Drain Plug *3 Rear Cover Plug Attachment Installation Position NOTE: Place the height adjustment attachment and plate lift attachment so that the engine assembly with transaxle is level. Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand. To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments onto the No. 2 oil pan sub-assembly of the engine assembly. Do not place any attachments onto the drain plug and rear cover plug of the hybrid vehicle transaxle assembly. Remove the bolt and 2 nuts, and separate the engine mounting insulator sub-assembly RH from the engine assembly. Remove the bolt and nut, and separate the engine mounting insulator LH from the engine mounting bracket LH. Remove the 6 bolts, operate the engine lifter and slowly remove the engine assembly with transaxle and front suspension crossmember sub-assembly from the vehicle. NOTE: Make sure that the engine is clear of all wiring and hoses.
41. INSTALL NO. 1 ENGINE HANGER Install the 2 No. 1 engine hangers with 2 new bolts. Torque: 44 N*m (448 kgf*cm, 32 ft.*lbf) Part Name Part No. No. 1 engine hanger 12281-21090 Bolt 91672-81025
42. FIX ENGINE ASSEMBLY WITH TRANSAXLE Attach the sling device to the engine hangers and chain block. NOTE: Make sure that the sling angle is correct to prevent the engine assembly and engine hangers from being damaged or deformed. To enable removal of the engine assembly, adjust the positions of the height adjustment attachment and plate lift attachment and set them in place. TEXT IN ILLUSTRATION *1 No. 2 Oil Pan Sub-assembly *2 Drain Plug *3 Rear Cover Plug Attachment Installation Position NOTE: Place the height adjustment attachment and plate lift attachment so that the engine assembly with transaxle is level. Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand. To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments onto the No. 2 oil pan sub-assembly of the engine assembly. Do not place any attachments onto the drain plug and rear cover plug of the hybrid vehicle transaxle assembly. Using a rope or belt, secure the engine assembly with transaxle to the engine lifter. NOTE: Set the engine assembly with transaxle so that it is horizontal. Do not tighten the rope or belt with a tightening mechanism or any more than is necessary.
43. REMOVE ENGINE ASSEMBLY Disconnect the 4 clamps and No. 2 engine wire. Remove the 3 bolts and disconnect the 4 connectors, 7 clamps and wire harness from the hybrid vehicle transaxle assembly. Remove the 3 bolts, 2 wire harness clamp brackets and transmission control cable clamp from the hybrid vehicle transaxle assembly. TEXT IN ILLUSTRATION *1 Wire Harness Clamp Bracket *2 Transmission Control Cable Clamp Remove the bolt, nut and drive shaft heat insulator sub-assembly from the engine and drive shaft heat insulator bracket. Disconnect the clamp from the drive shaft heat insulator bracket. Remove the 2 bolts and drive shaft heat insulator bracket from the engine. Remove the 2 bolts and starter hole heat insulator from the engine. Disengage the claw and remove the flywheel housing side cover from the engine. Remove the 6 bolts and hybrid vehicle transaxle assembly. NOTE: To avoid damage to the knock pins, do not pry between the hybrid vehicle transaxle assembly and the engine. To prevent the splines of the damper from becoming misaligned, do not allow the transaxle to hit the damper during transaxle removal and installation.
44. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY Gently place the engine assembly onto wood blocks or equivalent. NOTE: Set the engine assembly so that it is horizontal. To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments onto the No. 2 oil pan sub-assembly of the engine assembly. This step should be done while hanging the engine assembly using the sling device and chain block. Remove the transmission input damper assembly See step 2 .
45. REMOVE FLYWHEEL SUB-ASSEMBLY Gently place the engine assembly onto wooden blocks or equivalent. NOTE: Set the engine assembly so that it is horizontal. To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments onto the No. 2 oil pan sub-assembly of the engine assembly. This step should be done while hanging the engine assembly using the sling device and chain block. Remove the flywheel sub-assembly See step 3 .
46. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH HINT: Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary. Remove the 3 bolts and engine mounting insulator sub-assembly RH.
47. REMOVE ENGINE MOUNTING INSULATOR LH HINT: Perform this procedure only when replacement of the engine mounting insulator LH is necessary. Disconnect the wire harness clamp. Remove the 5 bolts and engine mounting insulator LH.
48. INSTALL ENGINE STAND Using a sling device and chain block, install the engine stand to the engine assembly. NOTE: Make sure that the sling angle is correct to prevent the engine assembly and engine hangers from being damaged or deformed. Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.
49. DISCONNECT ENGINE WIRE Disconnect all of the clamps and connectors and remove the engine wire from the engine assembly.
50. REMOVE NO. 1 ENGINE HANGER Remove the 2 bolts and 2 No. 1 engine hangers.

HINT

Perform "Inspection After Repairs" after replacing the engine assembly, cylinder head sub-assembly camshaft, No. 2 camshaft, camshaft timing gear assembly, piston sub-assembly or piston ring. Refer to INITIALIZATION .

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1. INSTALL NO. 1 ENGINE HANGER See step 41
2. INSTALL ENGINE WIRE Connect all of the clamps and connectors and install the engine wire from the engine assembly.
3. REMOVE ENGINE STAND Using a chain block and sling device, secure the engine assembly. NOTE: Make sure that the sling angle is correct to prevent the engine assembly and engine hangers from being damaged or deformed. Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand. Remove the engine stand from the engine.
4. INSTALL ENGINE MOUNTING INSULATOR LH HINT: Perform this procedure only when replacement of the engine mounting insulator LH is necessary. Temporarily install the engine mounting insulator LH with the 5 bolts. Tighten the 5 bolts in the sequence shown in the illustration. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) Connect the wire harness clamp.
5. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH HINT: Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary. Temporarily install the engine mounting insulator sub-assembly RH with the 3 bolts. Tighten the 3 bolts in the sequence shown in the illustration. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf)
6. INSTALL FLYWHEEL SUB-ASSEMBLY Gently place the engine assembly onto wooden blocks or equivalent. NOTE: Set the engine assembly so that it is horizontal. To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments onto the No. 2 oil pan sub-assembly of the engine assembly. This step should be done while hanging the engine assembly using the sling device and chain block. Install the flywheel sub-assembly See step 2 .
7. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY Gently place the engine assembly onto wood blocks or equivalent. NOTE: Set the engine assembly so that it is horizontal. To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments onto the No. 2 oil pan sub-assembly of the engine assembly. This step should be done while hanging the engine assembly using the sling device and chain block. Install the transmission input damper assembly See step 3 .
8. INSTALL ENGINE ASSEMBLY Make sure that the knock pins are installed to the engine. TEXT IN ILLUSTRATION *1 Knock Pin Temporarily install the hybrid vehicle transaxle assembly to the engine with the 2 bolts. HINT: Temporarily tighten bolt B first. Fully tighten the 2 bolts in the order of A and B. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) NOTE: Make sure that the wire harness or similar items are not pinched between the contact surfaces. Do not forcibly pry on the hybrid vehicle transaxle. Make sure to align the hybrid vehicle transaxle so that the input shaft of the hybrid vehicle transaxle will be inserted straight into the inner splines of the transmission input damper. Do not apply grease either to the spline or to the input shaft. When inserting the input shaft of the hybrid vehicle transaxle into the inner splines of the transmission input damper, do not shake the hybrid vehicle transaxle excessively. When mounting the hybrid vehicle transaxle to the engine, make sure to securely fit the knock pins into the knock holes. When tightening the bolts, be sure that the mating surfaces of the engine and the hybrid vehicle transaxle assembly are in close contact with one another. Bolt Length 45 mm (1.77 in.) Install the 4 bolts. Torque: 30 N*m (301 kgf*cm, 22 ft.*lbf) Bolt Length 45 mm (1.77 in.) Engage the claw and install the flywheel housing side cover to the engine. Install the starter hole heat insulator to the engine with the 2 bolts. Torque: 30 N*m (301 kgf*cm, 22 ft.*lbf) Bolt Length 45 mm (1.77 in.) Install the drive shaft heat insulator bracket to the engine with the 2 bolts. Torque: 30 N*m (301 kgf*cm, 22 ft.*lbf) Bolt Length 45 mm (1.77 in.) Connect the clamp to the drive shaft heat insulator bracket. Install the drive shaft heat insulator sub-assembly to the engine and drive shaft heat insulator bracket with the bolt and nut. Torque: 18 N*m (179 kgf*cm, 13 ft.*lbf) Install the 2 wire harness clamp brackets and transmission control cable clamp to the hybrid vehicle transaxle assembly with the 3 bolts. TEXT IN ILLUSTRATION *1 Wire Harness Clamp Bracket *2 Transmission Control Cable Clamp Bolt A Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) Bolt B Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) Connect the 7 clamps, 4 connectors and install the wire harness to the hybrid vehicle transaxle assembly with the 3 bolts. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) Connect the 4 clamps and No. 2 engine wire.
9. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE Using a sling device and chain block, set the engine assembly with transaxle on the engine lifter. NOTE: Place the height adjustment attachment and plate lift attachment so that the engine assembly with transaxle is level. Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand. To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments onto the No. 2 oil pan sub-assembly of the engine assembly. Do not place any attachments onto the drain plug and rear cover plug of the hybrid vehicle transaxle assembly. Make sure to support the engine assembly with transaxle securely to prevent it from falling. Remove the 2 bolts and 2 No. 1 engine hangers. Operate the engine lifter and lift the engine assembly with transaxle and front suspension crossmember to the position where the engine mounting insulator sub-assembly RH and engine mounting insulator LH can be installed. WARNING: Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up. NOTE: Make sure that the engine is clear of all wiring and hoses. Operate the engine lifter and lift the engine assembly with transaxle and front suspension crossmember to the position where the front suspension crossmember can be installed. By inserting SST into the datum holes in the front suspension crossmember RH and LH alternately, temporarily install the front suspension crossmember with the 6 bolts. TEXT IN ILLUSTRATION *a CORRECT *b INCORRECT *c Datum Hole - - SST: 09670-00010 Connect the engine mounting insulator LH with the bolt and nut to the engine assembly. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) Connect the engine mounting insulator sub-assembly RH with the bolt and 2 nuts to the engine assembly. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) Using several steps, uniformly tighten the 6 bolts. Bolt A Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) Bolt B Torque: 151 N*m (1539 kgf*cm, 111 ft.*lbf) Bolt C Torque: 98 N*m (999 kgf*cm, 72 ft.*lbf)
10. INSTALL FLYWHEEL HOUSING UNDER COVER Install the flywheel housing under cover.
11. INSTALL FRONT DRIVE SHAFT ASSEMBLY Refer to «INSTALLATION»(/toyota/prius-c/i-2011-2015/remont/axle-shafts/#drive-shaft-propeller-shaftfront-service-information__installation)
12. INSTALL NO. 2 ENGINE ROOM RELAY BLOCK AND NO. 2 JUNCTION BLOCK ASSEMBLY See step 4
13. INSTALL FRONT EXHAUST PIPE ASSEMBLY . Refer to «INSTALLATION - Step 8»(/toyota/prius-c/i-2011-2015/remont/exhaust/#intake-system-exhaust-system-service-information)
14. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY . Refer to «INSTALLATION - Step 2»(/toyota/prius-c/i-2011-2015/remont/automatic-hvac-system/#air-conditioning-system-service-information)
15. CONNECT SUCTION HOSE SUB-ASSEMBLY . Refer to «INSTALLATION - Step 3»(/toyota/prius-c/i-2011-2015/remont/automatic-hvac-system/#air-conditioning-system-service-information)
16. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE . Refer to «INSTALLATION - Step 4»(/toyota/prius-c/i-2011-2015/remont/automatic-hvac-system/#air-conditioning-system-service-information)
17. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY . Refer to «INSTALLATION - Step 4»(/toyota/prius-c/i-2011-2015/remont/manual-power-steering/#steering-gear-linkage-service-information)
18. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY . Refer to «INSTALLATION - Step 6»(/toyota/prius-c/i-2011-2015/remont/steering-column/#steering-column-service-information)
19. INSTALL COLUMN HOLE COVER SILENCER SHEET . Refer to «INSTALLATION - Step 8»(/toyota/prius-c/i-2011-2015/remont/steering-column/#steering-column-service-information)
20. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY . Refer to «INSTALLATION - Step 24»(/toyota/prius-c/i-2011-2015/remont/automatic-trans/#hybrid-transaxle-service-information)
21. CONNECT ENGINE WIRE Connect the wire harness clamp. Connect the engine wire to the engine room main wire. Connect the engine wire to the engine room relay block and junction block assembly and engage the claw. Connect the wire harness clamp and 2 connectors. Connect the 2 wire harness clamps. Connect the ECM connector and lower the lever. NOTE: When connecting the connector, make sure that dirt, water or other foreign matter does not become stuck between the connector and other part. Make sure that the lever is securely locked.
22. CONNECT FUEL TUBE SUB-ASSEMBLY . Refer to «INSTALLATION - Step 5»(/toyota/prius-c/i-2011-2015/remont/fuel-system/#fuel-system-service-information)
23. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY Connect the fuel vapor feed hose assembly.
24. CONNECT HEATER WATER HOSE Connect the 2 heater water hoses.
25. CONNECT NO. 2 RADIATOR HOSE Connect the No. 2 radiator hose.
26. CONNECT NO. 1 RADIATOR HOSE Connect the No. 1 radiator hose. TEXT IN ILLUSTRATION *a Up *b for LH Side *c Do Not Position Hose Clamp Claws In This Area HINT: Make sure that the claws on the hose clamp are positioned as shown in the illustration.
27. INSTALL INVERTER BRACKET ASSEMBLY WARNING: Wear insulated gloves. Temporarily install the inverter bracket assembly with the 4 bolts. Tighten the 4 bolts in the sequence shown in the illustration. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Connect the earth wire with the bolt. Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf) Install the inverter reservoir tank assembly with the 2 bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) Connect the 2 wire harness clamps. Connect the motor cable protector with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
28. INSTALL AIR CLEANER CASE SUB-ASSEMBLY . Refer to «INSTALLATION - Step 2»(/toyota/prius-c/i-2011-2015/remont/auxiliary-emission-control-systems/#emission-control-system-service-information)
29. INSTALL AIR CLEANER CAP SUB-ASSEMBLY . Refer to «INSTALLATION - Step 2»(/toyota/prius-c/i-2011-2015/remont/engine-control-systems/#engine-control-system-service-information)
30. INSTALL INVERTER WITH CONVERTER ASSEMBLY Refer to «INSTALLATION»(/toyota/prius-c/i-2011-2015/remont/engine-control-systems/#hybrid-battery-control-system-service-information__installation)
31. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to «INSTALLATION - Step 16»(/toyota/prius-c/i-2011-2015/remont/mechanical-hydraulic/#brake-system-hydraulic-service-information)
32. INSTALL FRONT NO. 1 VENTILATOR SEAL . Refer to «INSTALLATION - Step 17»(/toyota/prius-c/i-2011-2015/remont/mechanical-hydraulic/#brake-system-hydraulic-service-information)
33. INSTALL FRONT AIR SHUTTER SEAL . Refer to «INSTALLATION - Step 18»(/toyota/prius-c/i-2011-2015/remont/mechanical-hydraulic/#brake-system-hydraulic-service-information)
34. INSTALL INNER COWL TOP TO COWL BRACE . Refer to «INSTALLATION - Step 19»(/toyota/prius-c/i-2011-2015/remont/mechanical-hydraulic/#brake-system-hydraulic-service-information)
35. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Refer to «INSTALLATION»(/toyota/prius-c/i-2011-2015/remont/wiperwasher-systems/#wiper-system-washer-system-service-information__installation)
36. ADD COOLANT (for Engine) . Refer to «REPLACEMENT - Step 2»(/toyota/prius-c/i-2011-2015/remont/cooling-fan/#engine-cooling-system-service-information)
37. ADD COOLANT (for Inverter) . Refer to «REPLACEMENT - Step 2»(/toyota/prius-c/i-2011-2015/remont/engine-control-systems/#hybrid-battery-control-system-service-information)
38. ADD HYBRID TRANSAXLE FLUID . Refer to «ADJUSTMENT - Step 2»(/toyota/prius-c/i-2011-2015/remont/automatic-trans/#hybrid-transaxle-service-information)
39. INSPECT HYBRID TRANSAXLE FLUID . Refer to «ON-VEHICLE INSPECTION - Step 1»(/toyota/prius-c/i-2011-2015/remont/automatic-trans/#hybrid-transaxle-service-information)
40. ADD ENGINE OIL . Refer to «REPLACEMENT - Step 4»(/toyota/prius-c/i-2011-2015/remont/lubrication-system/#lubrication-system-service-information)
41. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL Refer to «INSTALLATION»(/toyota/prius-c/i-2011-2015/remont/body-electrical/#12-volt-battery-service-information__installation)
42. INSTALL SERVICE PLUG GRIP Refer to «INSTALLATION»(/toyota/prius-c/i-2011-2015/remont/engine-control-systems/#hybrid-battery-control-system-service-information)
43. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT . Refer to «REPLACEMENT - Step 2»(/toyota/prius-c/i-2011-2015/remont/automatic-hvac-system/#air-conditioning-system-service-information)
44. WARM UP COMPRESSOR . Refer to «REPLACEMENT - Step 3»(/toyota/prius-c/i-2011-2015/remont/automatic-hvac-system/#air-conditioning-system-service-information)
45. INSPECT FOR REFRIGERANT LEAK . Refer to «REPLACEMENT - Step 4»(/toyota/prius-c/i-2011-2015/remont/automatic-hvac-system/#air-conditioning-system-service-information)
46. CHECK ENGINE OIL LEVEL . Refer to «ON-VEHICLE INSPECTION - Step 1»(/toyota/prius-c/i-2011-2015/remont/lubrication-system/#lubrication-system-inspection)
47. INSPECT FOR FUEL LEAK . Refer to «ON-VEHICLE INSPECTION - Step 1»(/toyota/prius-c/i-2011-2015/remont/fuel-system/#fuel-system-inspection)
48. INSPECT FOR COOLANT LEAK (for Engine) . Refer to «ON-VEHICLE INSPECTION - Step 1»(/toyota/prius-c/i-2011-2015/remont/cooling-fan/#engine-cooling-system-inspection)
49. INSPECT FOR COOLANT LEAK (for Inverter) . Refer to «ON-VEHICLE INSPECTION - Step 1»(/toyota/prius-c/i-2011-2015/remont/engine-control-systems/#hybrid-battery-control-system-service-information)
50. INSPECT FOR HYBRID TRANSAXLE FLUID LEAK
51. INSPECT FOR OIL LEAK
52. INSPECT FOR EXHAUST GAS LEAK
53. INSPECT IGNITION TIMING See step 6
54. INSPECT ENGINE IDLE SPEED See step 7
55. INSPECT CO/HC See step 9
56. INSPECT AND ADJUST SHIFT LEVER POSITION Refer to «ADJUSTMENT»(/toyota/prius-c/i-2011-2015/remont/automatic-trans/#hybrid-transaxle-service-information)
57. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT Refer to «ADJUSTMENT»(/toyota/prius-c/i-2011-2015/remont/suspension-front/#wheel-alignment-inspection-adjustment)
58. CHECK ABS SPEED SENSOR SIGNAL Refer to «TEST MODE PROCEDURE»(/toyota/prius-c/i-2011-2015/remont/anti-locktraction-control/#electronically-controlled-brake-system-diagnostics-introduction)
59. INSTALL ENGINE UNDER COVER RH
60. INSTALL ENGINE UNDER COVER LH

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Scheme 173

1. REMOVE NO. 2 EGR PIPE . Refer to «REMOVAL - Step 2»(/toyota/prius-c/i-2011-2015/remont/auxiliary-emission-control-systems/#emission-control-system-service-information)
2. REMOVE EGR COOLER ASSEMBLY . Refer to «REMOVAL - Step 8»(/toyota/prius-c/i-2011-2015/remont/auxiliary-emission-control-systems/#emission-control-system-service-information)
3. REMOVE INTAKE MANIFOLD STAY . Refer to «REMOVAL - Step 5»(/toyota/prius-c/i-2011-2015/remont/exhaust/#intake-system-exhaust-system-service-information)
4. REMOVE INTAKE MANIFOLD . Refer to «REMOVAL - Step 6»(/toyota/prius-c/i-2011-2015/remont/exhaust/#intake-system-exhaust-system-service-information)
5. 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)
6. REMOVE MANIFOLD SUPPORT BRACKET . Refer to «REMOVAL - Step 5»(/toyota/prius-c/i-2011-2015/remont/exhaust/#intake-system-exhaust-system-service-information)
7. REMOVE EXHAUST MANIFOLD . Refer to «REMOVAL - Step 7»(/toyota/prius-c/i-2011-2015/remont/exhaust/#intake-system-exhaust-system-service-information)
8. REMOVE NO. 4 WATER BY-PASS HOSE Disconnect the No. 4 water by-pass hose. Remove the bolt and No. 4 water by-pass hose.
9. REMOVE NO. 1 WATER BY-PASS PIPE Disconnect the water hose from the water inlet with thermostat sub-assembly. Remove the 3 bolts and No. 1 water by-pass pipe.
10. REMOVE WIRE HARNESS CLAMP BRACKET Remove the bolt and wire harness clamp bracket.
11. REMOVE STUD BOLT Using an E7 "TORX" socket wrench, remove the stud bolt.
12. REMOVE ENGINE OIL LEVEL DIPSTICK Remove the engine oil level dipstick.
13. REMOVE IGNITION COIL ASSEMBLY . Refer to «REMOVAL - Step 1»(/toyota/prius-c/i-2011-2015/remont/engine-control-systems/#engine-control-system-service-information)

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1. REMOVE SPARK PLUG . Refer to «REMOVAL - Step 2»(/toyota/prius-c/i-2011-2015/remont/engine-control-systems/#engine-control-system-service-information)
2. REMOVE OIL FILLER CAP SUB-ASSEMBLY Remove the oil filler cap sub-assembly from the cylinder head cover.
3. REMOVE OIL FILLER CAP GASKET Using a screwdriver, remove the oil filler cap gasket from the oil filler cap. TEXT IN ILLUSTRATION *1 Protective Tape HINT: Wrap the screwdriver tip with protective tape before use.
4. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE . Refer to «REMOVAL - Step 10»(/toyota/prius-c/i-2011-2015/remont/lubrication-system/#lubrication-system-service-information)
5. REMOVE CAMSHAFT POSITION SENSOR Remove the bolt and camshaft position sensor.
6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Remove the bolt and camshaft timing oil control valve assembly. Remove the O-ring from the camshaft timing oil control valve assembly.
7. REMOVE KNOCK CONTROL SENSOR Remove the bolt and knock control sensor.
8. REMOVE ENGINE COOLANT TEMPERATURE SENSOR Using a 19 mm union nut wrench, remove the engine coolant temperature sensor and gasket.
9. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.
10. REMOVE OIL FILTER SUB-ASSEMBLY . Refer to «REPLACEMENT - Step 2»(/toyota/prius-c/i-2011-2015/remont/lubrication-system/#lubrication-system-service-information)
11. REMOVE CRANKSHAFT POSITION SENSOR Remove the bolt and crankshaft position sensor.
12. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY Remove the 2 bolts and water inlet with thermostat sub-assembly. Remove the gasket from the water inlet with thermostat sub-assembly.
13. REMOVE ENGINE WATER PUMP ASSEMBLY Remove the 5 bolts and engine water pump assembly. Remove the gasket from the engine water pump assembly.
14. REMOVE WATER INLET HOUSING Remove the bolt, 2 nuts and water inlet housing. Remove the gasket.
15. REMOVE ENGINE MOUNTING BRACKET RH . Refer to «REMOVAL - Step 11»(/toyota/prius-c/i-2011-2015/remont/lubrication-system/#lubrication-system-service-information)
16. REMOVE VENTILATION VALVE SUB-ASSEMBLY Using a 19 mm deep socket wrench, remove the ventilation valve sub-assembly from the cylinder head cover sub-assembly.
17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY Remove the 9 bolts, 2 seal washers, 2 nuts and cylinder head cover sub-assembly. Remove the gasket from the cylinder head cover sub-assembly.
18. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY Set the No. 1 cylinder to TDC/compression. Turn the crankshaft damper until its notch and timing mark "0" of the timing chain cover are aligned. Check that the timing marks on both the camshaft timing sprocket and the camshaft timing gear are facing upward as shown in the illustration. TEXT IN ILLUSTRATION *a Timing Mark *b Timing Mark (Rectangle) *c Mark (Circle) *d Timing Notch HINT: There are 3 marks on the camshaft timing sprocket. Make sure that the timing mark (rectangle) is at the top. If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above. Using SST, hold the crankshaft damper sub-assembly in place and loosen the bolt. 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 chain cover. Using SST, remove the crankshaft damper sub-assembly and bolt. SST: 09950-50013 09951-05010 09952-05010 09953-05020 09954-05021 HINT: Apply a lubricant to the threads and end of SST. Remove the crankshaft straight pin.
19. REMOVE TIMING CHAIN COVER . Refer to «REMOVAL - Step 13»(/toyota/prius-c/i-2011-2015/remont/lubrication-system/#lubrication-system-service-information)
20. REMOVE SCREW PLUG . Refer to «REMOVAL - Step 12»(/toyota/prius-c/i-2011-2015/remont/lubrication-system/#lubrication-system-service-information)
21. REMOVE OIL PUMP SEAL . Refer to «REMOVAL - Step 14»(/toyota/prius-c/i-2011-2015/remont/lubrication-system/#lubrication-system-service-information)
22. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY See step 7
23. REMOVE CHAIN TENSIONER SLIPPER See step 8
24. REMOVE NO. 1 CHAIN VIBRATION DAMPER See step 9
25. REMOVE CHAIN SUB-ASSEMBLY See step 10
26. REMOVE FUEL DELIVERY PIPE Remove the 3 bolts and fuel delivery pipe.
27. REMOVE FUEL DELIVERY SPACER . Refer to «REMOVAL - Step 12»(/toyota/prius-c/i-2011-2015/remont/fuel-system/#fuel-system-service-information)
28. REMOVE INJECTOR VIBRATION INSULATOR . Refer to «REMOVAL - Step 13»(/toyota/prius-c/i-2011-2015/remont/fuel-system/#fuel-system-service-information)
29. REMOVE FUEL INJECTOR ASSEMBLY . Refer to «REMOVAL - Step 14»(/toyota/prius-c/i-2011-2015/remont/fuel-system/#fuel-system-service-information)
30. REMOVE NO. 2 CAMSHAFT Using several steps, uniformly loosen and remove the 11 bolts in the sequence shown in the illustration. Then remove the No. 1 camshaft bearing cap and 4 No. 2 camshaft bearing caps. NOTE: Uniformly loosen the bolts while keeping the No. 2 camshaft level.
31. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET Clamp the No. 2 camshaft in a vise. NOTE: Be careful not to damage the No. 2 camshaft. Remove the bolt and camshaft timing gear or sprocket.
32. REMOVE CAMSHAFT Using several steps, uniformly loosen and remove the 8 bolts in the sequence shown in the illustration. Then remove the 4 No. 2 camshaft bearing caps. NOTE: Uniformly loosen the bolts while keeping the camshaft level.
33. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY See step 9
34. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY See step 10
35. REMOVE CYLINDER HEAD SUB-ASSEMBLY See step 12
36. REMOVE CYLINDER HEAD GASKET See step 13
37. REMOVE OIL FILTER UNION Using a 12 mm hexagon socket wrench, remove the oil filter union.
38. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY Remove the oil pan drain plug and gasket. Remove the 9 bolts and 2 nuts. Insert the blade of an oil pan seal cutter between the oil pan and No. 2 oil pan sub-assembly, cut the sealer and remove the No. 2 oil pan sub-assembly. NOTE: Be careful not to damage the oil pan and No. 2 oil pan sub-assembly.
39. REMOVE OIL STRAINER SUB-ASSEMBLY Remove the bolt, 2 nuts, oil strainer sub-assembly and gasket.
40. REMOVE OIL PAN SUB-ASSEMBLY Loosen and remove the 13 bolts uniformly in several steps. Using a screwdriver, remove the oil pan sub-assembly by prying between the cylinder block and oil pan sub-assembly. TEXT IN ILLUSTRATION *1 Protective Tape NOTE: Be careful not to damage the contact surfaces of the oil pan sub-assembly and cylinder block. HINT: Wrap the screwdriver tip with protective tape before use. Remove the 2 O-rings from the cylinder block. Using an E5 "TORX" socket wrench, remove the 4 stud bolts.
41. REMOVE REAR ENGINE OIL SEAL Remove the rear engine oil seal.

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1. INSPECT CHAIN SUB-ASSEMBLY Using a spring scale, pull the chain sub-assembly with a force of 140 N (14.3 kgf, 31.5 lbf) and measure the length of it. TEXT IN ILLUSTRATION *a Measuring Area Maximum length 124.2 mm (4.89 in.) If the length is greater than the maximum, replace the chain sub-assembly. HINT: Perform the measurement at 3 or more random places to obtain the average length.
2. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY Check that the plunger moves smoothly when the ratchet pawl is raised with your finger. TEXT IN ILLUSTRATION *1 Ratchet Pawl Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.
3. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY Wrap the chain sub-assembly around the camshaft timing gear assembly. Using a vernier caliper, measure the diameter of the camshaft timing gear assembly with the chain sub-assembly. Standard diameter 97.4 mm (3.83 in.) Minimum diameter 96.2 mm (3.79 in.) NOTE: The vernier caliper must come into contact with the chain rollers when measuring. If the diameter is less than the minimum, replace the camshaft timing gear assembly.
4. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET Wrap the chain sub-assembly around the camshaft timing gear or sprocket. Using a vernier caliper, measure the diameter of the camshaft timing gear or sprocket with the chain sub-assembly. Standard diameter 97.4 mm (3.83 in.) Minimum diameter 96.2 mm (3.79 in.) NOTE: The vernier caliper must come into contact with the chain rollers when measuring. If the diameter is less than the minimum, replace the camshaft timing gear or sprocket.
5. INSPECT CHAIN TENSIONER SLIPPER Measure the chain tensioner slipper wear. Maximum wear 1.0 mm (0.0394 in.) If the wear is greater than the maximum, replace the chain tensioner slipper.
6. INSPECT NO. 1 CHAIN VIBRATION DAMPER Measure the vibration damper wear. Maximum wear 1.0 mm (0.0394 in.) If the wear is greater than the maximum, replace the No. 1 chain vibration damper.
7. INSPECT CYLINDER HEAD SET BOLT Using a vernier caliper, measure the length of the cylinder head set bolts from the seat to the end. TEXT IN ILLUSTRATION *a Length Standard length 142.8 to 144.2 mm (5.62 to 5.68 in.) Maximum length 147.1 mm (5.79 in.) If the length is greater than the maximum, replace the cylinder head set bolt.
8. INSPECT EXHAUST MANIFOLD Using a precision straightedge and feeler gauge, measure the surface contacting the exhaust manifold for warpage. Maximum warpage 0.7 mm (0.0276 in.) If the warpage is greater than the maximum, replace the exhaust manifold.

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1. INSTALL OIL PAN SUB-ASSEMBLY HINT: If a stud bolt is deformed or the threads are damaged, replace it. Using an E5 "TORX" socket wrench, install the 4 stud bolts. TEXT IN ILLUSTRATION *a 13 mm (0.512 in.) *b 8 mm (0.315 in.) *c 22.5 mm (0.886 in.) *d 16.5 mm (0.650 in.) *e 9 mm (0.354 in.) *f 27.5 mm (1.08 in.) Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) Apply seal packing to the oil pan sub-assembly as shown in the illustration. TEXT IN ILLUSTRATION *a Apply Seal Packing *b 4 mm (0.157 in.) *c 11 mm (0.433 in.) *d 9 mm (0.354 in.) Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter 2.0 to 3.0 mm (0.0787 to 0.118 in.) NOTE: When the contact surfaces are wet, clean the surfaces with non-residue solvent before applying seal packing. Install the oil pan sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying seal packing. Do not apply engine oil for at least 2 hours after installation. Install 2 new O-rings to the cylinder block and temporarily install the oil pan sub-assembly with the 13 bolts. NOTE: When the contact surfaces are wet, clean the surfaces with non-residue solvent before applying seal packing. Be careful that the O-ring is not cracked or moved out of place when installing the oil pan sub-assembly. Using several steps, uniformly tighten the 13 bolts in the sequence shown in the illustration. Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) Item Length Of The Bolt From The Seat To The End. Bolt A 49 mm (1.93 in.) Bolt B 88 mm (3.46 in.) Bolt C 143.7 mm (5.66 in.)
2. INSTALL REAR ENGINE OIL SEAL See step 1
3. INSTALL OIL STRAINER SUB-ASSEMBLY Install a new gasket and the oil strainer sub-assembly with the 2 nuts and bolt. Torque: 13 N*m (132 kgf*cm, 10 ft.*lbf)
4. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY Apply seal packing to the No. 2 oil pan sub-assembly as shown in the illustration below. TEXT IN ILLUSTRATION *a Apply Seal Packing Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter 2.5 to 3.5 mm (0.0984 to 0.138 in.) NOTE: When the contact surfaces are wet, clean the surfaces with non-residue solvent before applying seal packing. Install the No. 2 oil pan sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing. Do not apply engine oil for at least 2 hours after installation. Install the No. 2 oil pan sub-assembly with the 9 bolts and 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) Install the oil pan drain plug with a new gasket. Torque: 38 N*m (382 kgf*cm, 28 ft.*lbf)
5. INSTALL OIL FILTER UNION Using a 12 mm hexagon socket wrench, install the oil filter union. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
6. INSTALL OIL FILTER SUB-ASSEMBLY . Refer to «REPLACEMENT - Step 3»(/toyota/prius-c/i-2011-2015/remont/lubrication-system/#lubrication-system-service-information)
7. INSTALL CYLINDER HEAD GASKET See step 2
8. INSTALL CYLINDER HEAD SUB-ASSEMBLY See step 3
9. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY See step 1
10. 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 and cylinder head sub-assembly journals. Place the camshaft on the cylinder head sub-assembly with the timing mark on the camshaft timing gear assembly facing upward. TEXT IN ILLUSTRATION *a 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.
11. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET Clamp the No. 2 camshaft in a vise. NOTE: Be careful not to damage the No. 2 camshaft. Align the knock pin hole of the camshaft timing gear or sprocket with the knock pin of the No. 2 camshaft, and tighten the camshaft timing gear or sprocket with the bolt. Torque: 64 N*m (652 kgf*cm, 47 ft.*lbf)
12. 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 and cylinder head sub-assembly journals. Place the No. 2 camshaft on the cylinder head with the timing mark on the camshaft timing gear or sprocket facing upward. TEXT IN ILLUSTRATION *a Timing Mark (Rectangle) *b Mark (Circle) HINT: There are 3 marks on the camshaft timing gear or sprocket. Make sure that the timing mark (rectangle) is at the top. 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.
13. INSTALL CHAIN SUB-ASSEMBLY See step 5
14. INSTALL OIL PUMP SEAL See step 1
15. INSTALL SCREW PLUG . Refer to «INSTALLATION - Step 3»(/toyota/prius-c/i-2011-2015/remont/lubrication-system/#lubrication-system-service-information)
16. INSTALL TIMING CHAIN COVER . Refer to «INSTALLATION - Step 2»(/toyota/prius-c/i-2011-2015/remont/lubrication-system/#lubrication-system-service-information)
17. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY Install the straight pin to the crankshaft. 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. SST: 09213-58012 91111-50845 SST: 09330-00021 Torque: 128 N*m (1, 305 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.
18. INSTALL ENGINE MOUNTING BRACKET RH . Refer to «INSTALLATION - Step 4»(/toyota/prius-c/i-2011-2015/remont/lubrication-system/#lubrication-system-service-information)
19. INSTALL WATER INLET HOUSING Install a new gasket to the water inlet housing. Temporarily install the water inlet housing with the bolt and 2 nuts. Tighten the bolt and 2 nuts in the sequence shown in the illustration. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
20. INSTALL ENGINE WATER PUMP ASSEMBLY Install a new gasket to the engine water pump assembly. NOTE: When the contact surfaces are wet, clean the surfaces with non-residue solvent before applying seal packing. Install the engine water pump assembly with the 5 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
21. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY Install a new gasket to the water inlet with thermostat sub-assembly. Install the water inlet with thermostat sub-assembly with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
22. INSPECT VALVE CLEARANCE See step 3
23. ADJUST VALVE CLEARANCE See step 4
24. INSTALL FUEL INJECTOR ASSEMBLY . Refer to «INSTALLATION - Step 1»(/toyota/prius-c/i-2011-2015/remont/fuel-system/#fuel-system-service-information)
25. INSTALL INJECTOR VIBRATION INSULATOR . Refer to «INSTALLATION - Step 2»(/toyota/prius-c/i-2011-2015/remont/fuel-system/#fuel-system-service-information)
26. INSTALL FUEL DELIVERY SPACER . Refer to «INSTALLATION - Step 3»(/toyota/prius-c/i-2011-2015/remont/fuel-system/#fuel-system-service-information)
27. INSTALL FUEL DELIVERY PIPE Install the fuel delivery pipe with the 3 bolts. Bolt A Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Bolt B Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE: Be careful not to drop the fuel injectors when installing the fuel delivery pipe. Check that the fuel injectors rotate smoothly after installing the fuel delivery pipe.
28. 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)
29. INSTALL VENTILATION VALVE SUB-ASSEMBLY Apply adhesive to 2 or 3 threads of the ventilation valve sub-assembly. Adhesive Toyota genuine adhesive 1324, three bond 1324 or equivalent Using a 19 mm deep socket wrench, install the ventilation valve sub-assembly. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)
30. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE . Refer to «INSTALLATION - Step 5»(/toyota/prius-c/i-2011-2015/remont/lubrication-system/#lubrication-system-service-information)
31. INSTALL OIL FILLER CAP GASKET Install a new oil filler cap gasket to the oil filler cap.
32. INSTALL OIL FILLER CAP SUB-ASSEMBLY Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.
33. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY Apply adhesive to 2 or 3 threads of the engine oil pressure switch assembly. Adhesive Toyota genuine adhesive 1344, three bond 1344 or equivalent Using a 24 mm deep socket wrench, install the engine oil pressure switch assembly. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) NOTE: Do not start the engine within 1 hour of installation.
34. INSTALL ENGINE COOLANT TEMPERATURE SENSOR Using a 19 mm union nut wrench, install a new gasket and the engine coolant temperature sensor. Torque: 20 N*m (204 kgf*cm, 15 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) .
35. INSTALL KNOCK CONTROL SENSOR Install the knock control sensor with the bolt. TEXT IN ILLUSTRATION Up Engine Front Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) NOTE: Make sure that the knock control sensor is as shown in the illustration.
36. INSTALL CRANKSHAFT POSITION SENSOR Apply a light coat of engine oil to a new O-ring and install it to the crankshaft position sensor. NOTE: If the O-ring is damaged, replace the crankshaft position sensor. Install the crankshaft position sensor with the bolt. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
37. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Apply a light coat of engine oil to a new O-ring and install it to the camshaft timing oil control valve assembly. Install the camshaft timing oil control valve assembly with the bolt. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
38. INSTALL CAMSHAFT POSITION SENSOR Apply a light coat of engine oil to the O-ring on the camshaft position sensor. NOTE: If the O-ring is damaged, replace the camshaft position sensor. Install the camshaft position sensor with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
39. INSTALL SPARK PLUG . Refer to «INSTALLATION - Step 1»(/toyota/prius-c/i-2011-2015/remont/engine-control-systems/#engine-control-system-service-information)

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1. INSTALL IGNITION COIL ASSEMBLY . Refer to «INSTALLATION - Step 2»(/toyota/prius-c/i-2011-2015/remont/engine-control-systems/#engine-control-system-service-information)
2. INSTALL ENGINE OIL LEVEL DIPSTICK Install the engine oil level dipstick.
3. INSTALL STUD BOLT Using an E7 "TORX" socket wrench, install the stud bolt. TEXT IN ILLUSTRATION *a 18.0 mm (0.709 in.) *b 13.0 mm (0.512 in.) *c 33.0 mm (1.30 in.) Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
4. INSTALL WIRE HARNESS CLAMP BRACKET Install the wire harness clamp bracket with the bolt. Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf)
5. INSTALL NO. 1 WATER BY-PASS PIPE Install the No. 1 water by-pass pipe with the 3 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the water hose.
6. INSTALL NO. 4 WATER BY-PASS HOSE Install the No. 4 water by-pass hose with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the No. 4 water by-pass hose.
7. INSTALL EXHAUST MANIFOLD . Refer to «INSTALLATION - Step 3»(/toyota/prius-c/i-2011-2015/remont/exhaust/#intake-system-exhaust-system-service-information)
8. INSTALL MANIFOLD SUPPORT BRACKET . Refer to «INSTALLATION - Step 5»(/toyota/prius-c/i-2011-2015/remont/exhaust/#intake-system-exhaust-system-service-information)
9. 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)
10. INSTALL INTAKE MANIFOLD . Refer to «INSTALLATION - Step 1»(/toyota/prius-c/i-2011-2015/remont/exhaust/#intake-system-exhaust-system-service-information)
11. INSTALL INTAKE MANIFOLD STAY . Refer to «INSTALLATION - Step 2»(/toyota/prius-c/i-2011-2015/remont/exhaust/#intake-system-exhaust-system-service-information)
12. INSTALL EGR COOLER ASSEMBLY . Refer to «INSTALLATION - Step 1»(/toyota/prius-c/i-2011-2015/remont/auxiliary-emission-control-systems/#emission-control-system-service-information)
13. INSTALL NO. 2 EGR PIPE . Refer to «INSTALLATION - Step 2»(/toyota/prius-c/i-2011-2015/remont/auxiliary-emission-control-systems/#emission-control-system-service-information)

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1. REMOVE TAPER SCREW PLUG Using a 10 mm hexagon wrench, remove the taper screw plug and gasket. HINT: If water leaks from the taper screw plug or the plug is corroded, replace it.
2. REMOVE OIL CONTROL VALVE FILTER Using an 8 mm hexagon wrench, remove the straight screw plug. HINT: If water leaks from the straight screw plug or the plug is corroded, replace it. Remove the oil control valve filter and gasket.
3. REMOVE VALVE LIFTER Remove the 16 valve lifters. HINT: Arrange the valve lifters in the correct order.
4. REMOVE INTAKE VALVE Using SST and wooden blocks, remove the 16 retainer locks. SST: 09202-70020 09202-00010 09202-01010 09202-01020 HINT: Arrange the removed parts in the correct order. Remove the 8 retainers, 8 compression springs and 8 intake valves. HINT: Arrange the removed parts in the correct order.
5. REMOVE EXHAUST VALVE Using SST and wooden blocks, remove the 16 retainer locks. SST: 09202-70020 09202-00010 09202-01010 09202-01020 HINT: Arrange the removed parts in the correct order. Remove the 8 retainers, 8 compression springs and 8 exhaust valves. HINT: Arrange the removed parts in the correct order.
6. REMOVE VALVE STEM OIL SEAL Using needle-nose pliers, remove the 16 valve stem oil seals.
7. REMOVE VALVE SPRING SEAT Using compressed air and a Magnet Hand, remove the 16 valve spring seats by blowing air onto them.

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1. INSPECT CYLINDER HEAD FOR FLATNESS Using a precision straightedge and feeler gauge, measure the warpage of the contact surfaces where the cylinder head sub-assembly contacts the cylinder block and manifold. TEXT IN ILLUSTRATION *a Cylinder Block Side *b Intake Manifold Side *c Exhaust Manifold Side Maximum warpage Surface Specified Condition Cylinder block side 0.05 mm (0.00197 in.) Intake manifold side 0.10 mm (0.00394 in.) Exhaust manifold side 0.10 mm (0.00394 in.) If the warpage is greater than the maximum, replace the cylinder head sub-assembly.
2. INSPECT CYLINDER HEAD FOR CRACKS Using a dye penetrant, check the intake ports, exhaust ports and cylinder head sub-assembly surface for cracks. If cracked, replace the cylinder head sub-assembly.
3. INSPECT INTAKE VALVE Using a vernier caliper, measure the overall length of the intake valve. TEXT IN ILLUSTRATION *a Overall Length Standard overall length 89.25 mm (3.51 in.) Minimum overall length 88.95 mm (3.50 in.) If the overall length is less than the minimum, replace the intake valve. Using a micrometer, measure the diameter of the valve stem. Standard valve stem diameter 4.970 to 4.985 mm (0.19567 to 0.19626 in.) If the valve stem diameter is not as specified, check the oil clearance. Using a vernier caliper, measure the valve head margin thickness. TEXT IN ILLUSTRATION *a Margin Thickness Standard margin thickness 1.0 mm (0.0394 in.) Minimum margin thickness 0.7 mm (0.0276 in.) If the margin thickness is less than the minimum, replace the intake valve.
4. INSPECT EXHAUST VALVE Using a vernier caliper, measure the overall length of the exhaust valve. TEXT IN ILLUSTRATION *a Overall Length Standard overall length 87.90 mm (3.46 in.) Minimum overall length 87.60 mm (3.45 in.) If the overall length is less than the minimum, replace the exhaust valve. Using a micrometer, measure the diameter of the valve stem. Standard valve stem diameter 4.965 to 4.980 mm (0.19547 to 0.19606 in.) If the valve stem diameter is not as specified, check the oil clearance. Using a vernier caliper, measure the valve head margin thickness. TEXT IN ILLUSTRATION *a Margin Thickness Standard margin thickness 1.15 mm (0.0453 in.) Minimum margin thickness 0.85 mm (0.0335 in.) If the margin thickness is less than the minimum, replace the exhaust valve.
5. INSPECT COMPRESSION SPRING Using a vernier caliper, measure the free length of the compression spring. Standard free length 59.77 mm (2.35 in.) Using a steel square, measure the deviation of the compression spring. TEXT IN ILLUSTRATION *1 Steel Square *a Deviation Maximum deviation 1.6 mm (0.0630 in.)
6. INSPECT VALVE GUIDE BUSH OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the valve guide bush. Bush inside diameter 5.01 to 5.03 mm (0.197 to 0.198 in.) Subtract the valve stem diameter measurement from the valve guide bush inside diameter measurement. Standard oil clearance Valve Guide Bush 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 Guide Bush Specified Condition Intake 0.08 mm (0.00315 in.) Exhaust 0.10 mm (0.00394 in.) If the oil clearance is greater than the maximum, replace the valve and valve guide bush. Refer to «REPLACEMENT»(/toyota/prius-c/i-2011-2015/remont/mechanical/#engine-mechanical-service-information) .
7. INSPECT VALVE SEATS Apply a light coat of Prussian blue to the valve face. Lightly press the valve face against the valve seat. Check the valve face and seat according to the following procedure. TEXT IN ILLUSTRATION *a Width If Prussian blue appears 360° around the valve face, the valve face is concentric. If not, replace the valve. If Prussian blue appears 360° around the valve seat, the guide and valve face are concentric. If not, resurface the valve seat. Check that the valve seat contact is in the middle of the valve face with the valve seat width between 1.0 and 1.4 mm (0.0394 to 0.0551 in.).
8. INSPECT VALVE LIFTER Using a micrometer, measure the valve lifter diameter. Standard lifter diameter 30.966 to 30.976 mm (1.2191 to 1.2195 in.)
9. INSPECT VALVE LIFTER OIL CLEARANCE Using a caliper gauge, measure the valve lifter bore diameter of the cylinder head sub-assembly. Standard lifter bore diameter 31.009 to 31.025 mm (1.2208 to 1.2215 in.) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance 0.033 to 0.059 mm (0.00130 to 0.00232 in.) Maximum oil clearance 0.1 mm (0.00394 in.) If the oil clearance is greater than the maximum, replace the valve lifter. If necessary, replace the cylinder head sub-assembly.
10. INSPECT CAMSHAFT Inspect the camshaft for runout. Place the camshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout 0.03 mm (0.00118 in.) If the circle runout is greater than the maximum, replace the camshaft. Inspect the cam lobes. Using a micrometer, measure the cam lobe height. Standard cam lobe height 42.261 to 42.461 mm (1.6638 to 1.6717 in.) Minimum cam lobe height 42.16 mm (1.6598 in.) If the cam lobe height is less than the minimum, replace the camshaft. Inspect the camshaft journals. Using a micrometer, measure the journal diameter. Standard journal diameter Journal Specified Condition No. 1 journal 34.449 to 34.465 mm (1.3563 to 1.3569 in.) Other journals 22.949 to 22.965 mm (0.90350 to 0.90413 in.) If the journal diameter is not as specified, check the oil clearance.
11. INSPECT NO. 2 CAMSHAFT Inspect the camshaft for runout. Place the camshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout 0.03 mm (0.00118 in.) If the circle runout is greater than the maximum, replace the No. 2 camshaft. Inspect the cam lobes. Using a micrometer, measure the cam lobe height. Standard cam lobe height 44.046 to 44.146 (1.7341 to 1.7380 in.) Minimum cam lobe height 43.90 mm (1.7283 in.) If the cam lobe height is less than the minimum, replace the No. 2 camshaft. Inspect the camshaft journals. Using a micrometer, measure the journal diameter. Standard journal diameter Journal Specified Condition No. 1 journal 34.449 to 34.465 mm (1.3563 to 1.3569 in.) Other journals 22.949 to 22.965 mm (0.90350 to 0.90413 in.) If the journal diameter is not as specified, check the oil clearance.
12. INSPECT CAMSHAFT THRUST CLEARANCE Install the camshafts See step 4 . Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance 0.040 to 0.095 mm (0.00157 to 0.00374 in.) Maximum thrust clearance 0.11 mm (0.00433 in.) If the thrust clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft bearing caps and the cylinder head sub-assembly.
13. INSPECT CAMSHAFT OIL CLEARANCE NOTE: Do not turn the camshafts. Clean the camshaft bearing caps and the camshaft journals. Place the camshafts on the cylinder head sub-assembly. Lay a strip of Plastigage across each of the camshaft journals. TEXT IN ILLUSTRATION *1 Plastigage Install the camshaft bearing caps See step 4 . Remove the camshaft bearing caps See step 11 . Measure the Plastigage at its widest point. TEXT IN ILLUSTRATION *1 Plastigage Standard oil clearance 0.035 to 0.072 mm (0.00138 to 0.00283 in.) Maximum oil clearance 0.115 mm (0.00453 in.) If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft bearing caps and the cylinder head sub-assembly. NOTE: Completely remove the Plastigage.

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1. REPLACE STUD BOLT HINT: If any of the stud bolts is deformed or the threads are damaged, replace it. Using an E5 and E7 "TORX" socket wrench, replace the stud bolts. TEXT IN ILLUSTRATION *a Timing Chain Cover Side *b Intake Manifold Side *c Upper Side *d Exhaust Manifold Side *e 26.5 mm (1.04 in.) *f 12.0 mm (0.472 in.) *g 43.5 mm (1.71 in.) *h 19.5 mm (0.768 in.) *i 38.5 mm (1.52 in.) *j 28.5 mm (1.12 in.) *k 13.0 mm (0.512 in.) *l 49.5 mm (1.95 in.) *m 22.5 mm (0.886 in.) *n 37.5 mm (1.48 in.) Stud Bolt A Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Stud Bolt B Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) Stud Bolt C Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Stud Bolt D Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
2. REPLACE STRAIGHT PIN HINT: If a straight pin is deformed or the threads are damaged, replace it. Remove the straight pins. Using a plastic hammer, tap in new straight pins to the specified protrusion height. TEXT IN ILLUSTRATION *a Standard Protrusion Height Standard protrusion height 4.5 to 5.5 mm (0.177 to 0.217 in.)
3. REPLACE INTAKE VALVE GUIDE BUSH Heat the cylinder head to 80 to 100°C (176 to 212°F). Using SST and a hammer, tap out the intake valve guide bush. SST: 09201-10000 09201-01050 SST: 09950-70010 09951-07100 Using a caliper gauge, measure the bush bore diameter of the cylinder head sub-assembly. Standard bore diameter Bush size Specified Condition STD 9.685 to 9.706 mm (0.381 to 0.382 in.) O/S 0.05 9.735 to 9.756 mm (0.383 to 0.384 in.) If the bush bore diameter of the cylinder head sub-assembly is greater than 9.706 mm (0.382 in.), machine the bush bore to the dimension of 9.735 to 9.756 mm (0.383 to 0.384 in.) to install an O/S 0.05 valve guide bush. If the bush bore diameter of the cylinder head is greater than 9.756 mm (0.384 in.), replace the cylinder head sub-assembly. Heat the cylinder head sub-assembly to 80 to 100°C (176 to 212°F). Using SST and a hammer, tap a new intake valve guide bush into the specified protrusion height. TEXT IN ILLUSTRATION *a Standard Protrusion Height SST: 09201-10000 09201-01050 SST: 09950-70010 09951-07100 Standard protrusion height 9.0 to 9.4 mm (0.354 to 0.370 in.) Using a sharp 5 mm reamer, ream the intake valve guide bush to obtain the standard specified clearance between the intake valve guide bush and the valve stem. Standard oil clearance 0.025 to 0.060 mm (0.000984 to 0.00236 in.)
4. REPLACE EXHAUST VALVE GUIDE BUSH Heat the cylinder head to 80 to 100°C (176 to 212°F). Using SST and a hammer, tap out the exhaust valve guide bush. SST: 09201-10000 09201-01050 SST: 09950-70010 09951-07100 Using a caliper gauge, measure the bush bore diameter of the cylinder head sub-assembly. Standard bore diameter Bush size Specified Condition STD 9.685 to 9.706 mm (0.381 to 0.382 in.) O/S 0.05 9.735 to 9.756 mm (0.383 to 0.384 in.) If the bush bore diameter of the cylinder head sub-assembly is greater than 9.706 mm (0.382 in.), machine the bush bore to the dimension of 9.735 to 9.756 mm (0.383 to 0.384 in.) to install an O/S 0.05 valve guide bush. If the bush bore diameter of the cylinder head is greater than 9.756 mm (0.384 in.), replace the cylinder head sub-assembly. Heat the cylinder head sub-assembly to 80 to 100°C (176 to 212°F). Using SST and a hammer, tap a new exhaust valve guide bush into the specified protrusion height. TEXT IN ILLUSTRATION *a Standard Protrusion Height SST: 09201-10000 09201-01050 SST: 09950-70010 09951-07100 Standard protrusion height 9.0 to 9.4 mm (0.354 to 0.370 in.) Using a sharp 5 mm reamer, ream the exhaust valve guide bush to obtain the standard specified clearance between the exhaust valve guide bush and the valve stem. Standard oil clearance 0.030 to 0.065 mm (0.00118 to 0.00256 in.)

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1. INSTALL VALVE SPRING SEAT Install the 16 valve spring seats to the cylinder head sub-assembly.
2. INSTALL VALVE STEM OIL SEAL Apply a light coat of engine oil to a new valve stem oil seal. TEXT IN ILLUSTRATION *a Intake Side *b Exhaust Side *c Gray *d Black NOTE: Pay close attention when installing the intake and exhaust valve stem oil seals. For example, installing the intake valve stem oil seal to the exhaust side or installing the exhaust valve stem oil seal to the intake side can cause installation problems later. Using SST, push on the 16 valve stem oil seals. TEXT IN ILLUSTRATION *a CORRECT *b INCORRECT SST: 09201-41020 NOTE: Failure to use SST will cause the seal to be damaged or improperly seated.
3. INSTALL INTAKE VALVE Sufficiently apply engine oil to the tip area of the intake valve shown in the illustration. TEXT IN ILLUSTRATION *a 30 mm (1.18 in.) or more Install the 8 intake valves, 8 compression springs and 8 retainers to the cylinder head sub-assembly. NOTE: Install the same parts in the same combination to their original locations. Using SST and wooden blocks, compress the compression spring and install the 8 retainer locks. SST: 09202-70020 09202-00010 09202-01010 09202-01020 Using a pin punch and plastic hammer, lightly tap the valve stem tip to ensure a proper fit. NOTE: Be careful not to damage the valve stem tip.
4. INSTALL EXHAUST VALVE Sufficiently apply engine oil to the tip area of the exhaust valve shown in the illustration. TEXT IN ILLUSTRATION *a 30 mm (1.18 in.) or more Install the 8 exhaust valves, 8 compression springs and 8 retainers to the cylinder head sub-assembly. NOTE: Install the same parts in the same combination to their original locations. Using SST and wooden blocks, compress the compression spring and install the 8 retainer locks. SST: 09202-70020 09202-00010 09202-01010 09202-01020 Using a pin punch and plastic hammer, lightly tap the valve stem tip to ensure a proper fit. NOTE: Be careful not to damage the valve stem tip.
5. INSTALL VALVE LIFTER Apply a light coat of engine oil to the valve lifters. Install the 16 valve lifters. NOTE: Install the same parts in the same combination to their original locations. Check that the valve lifters rotate smoothly by hand.
6. INSTALL OIL CONTROL VALVE FILTER Check that no foreign matter is on the mesh part of the oil control valve filter. Using an 8 mm hexagon wrench, install the oil control valve filter with a new gasket and the straight screw plug. TEXT IN ILLUSTRATION *a Mesh Part Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
7. INSTALL TAPER SCREW PLUG Install a new gasket to the taper screw plug. Using a 10 mm hexagon wrench, install the taper screw plug. Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)

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1. REPAIR INTAKE VALVE SEATS NOTE: Repair the seat while checking the seating position. Keep the lip free of foreign matter. If the seating is too high on the valve face, use 20° and 45° cutters to correct the seat. TEXT IN ILLUSTRATION *a Width Valve seat width 1.0 to 1.4 mm (0.0394 to 0.0551 in.) If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat. TEXT IN ILLUSTRATION *a Width Valve seat width 1.0 to 1.4 mm (0.0394 to 0.0551 in.) Hand-lap the valve and valve seat with an abrasive compound. Check the valve seating position.
2. REPAIR EXHAUST VALVE SEATS NOTE: Repair the seat while checking the seating position. Keep the lip free of foreign matter. If the seating is too high on the valve face, use 20° and 45° cutters to correct the seat. TEXT IN ILLUSTRATION *a Width Valve seat width 1.0 to 1.4 mm (0.0394 to 0.0551 in.) If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat. TEXT IN ILLUSTRATION *a Width Valve seat width 1.0 to 1.4 mm (0.0394 to 0.0551 in.) Hand-lap the valve and valve seat with an abrasive compound. Check the valve seating position.

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1. INSPECT CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance 0.16 to 0.36 mm (0.00630 to 0.0142 in.) Maximum thrust clearance 0.36 mm (0.0142 in.) If the thrust clearance is greater than the maximum, replace the connecting rod.
2. INSPECT CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance 0.04 to 0.24 mm (0.00157 to 0.00945 in.) Maximum thrust clearance 0.3 mm (0.0118 in.) If the thrust clearance is greater than the maximum, replace the thrust washers as a set. REFERENCE Item Thrust Washer Thickness Thrust Clearance STD 2.43 to 2.48 mm (0.0957 to 0.0976 in.) 0.04 to 0.24 mm (0.00157 to 0.00945 in.) O/S 0.125 2.493 to 2.543 (0.0981 to 0.100 in.) 0.04 to 0.24 mm (0.00157 to 0.00945 in.) O/S 0.250 2.555 to 2.605 (0.101 to 0.103 in.) 0.04 to 0.24 mm (0.00157 to 0.00945 in.)
3. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD Using a ridge reamer, remove all carbon from the top of the cylinder. Mark each cylinder No. on the connecting rod and connecting rod cap with paint. Using SST, remove the 2 connecting rod cap bolts. SST: 09205-16010 Using the 2 removed connecting rod cap bolts, remove the connecting rod cap with connecting rod bearing by wiggling the connecting rod cap right and left. Clean the crank pin and connecting rod bearing. NOTE: Check the crank pin and connecting rod bearing for pitting and scratches. HINT: Keep the connecting rod bearing inserted in the connecting rod cap. Push the piston, connecting rod and connecting rod bearing through the top of the cylinder block. HINT: Keep each connecting rod bearing, connecting rod and connecting rod cap as a set. Arrange the removed parts in the correct order.
4. REMOVE CONNECTING ROD BEARING Remove the 8 connecting rod bearings. HINT: Arrange the removed parts in the correct order.
5. REMOVE PISTON RING SET Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring. Remove the oil ring and oil ring expander by hand. HINT: Arrange the removed parts in the correct order.
6. REMOVE PISTON SUB-ASSEMBLY WITH PISTON PIN Using SST, press out the piston pin from the piston. SST: 09221-25026 09221-00021 09221-00030 09221-00061 09221-00090 09221-00100 HINT: The piston and pin are a matched set. Arrange the removed parts in the correct order.
7. REMOVE CRANKSHAFT Using several steps, uniformly loosen and remove the 10 crankshaft bearing cap bolts with a 12 mm socket wrench for 12 pointed head in the sequence shown in the illustration. Using the 2 removed crankshaft bearing cap bolts, remove the 5 crankshaft bearing caps. HINT: Keep each No. 2 crankshaft bearing and crankshaft bearing cap as a set. Arrange the removed parts in the correct order. Remove the crankshaft from the cylinder block.
8. REMOVE UPPER CRANKSHAFT THRUST WASHER Remove the 2 upper crankshaft thrust washers from the cylinder block. HINT: Arrange the removed parts in the correct order.
9. REMOVE CRANKSHAFT BEARING Remove the 5 upper crankshaft bearings from the cylinder block. HINT: Arrange the removed parts in the correct order. Remove the 5 lower crankshaft bearings from the crankshaft bearing cap. HINT: Arrange the removed parts in the correct order.
10. REMOVE WATER BY-PASS HOSE UNION Using a 17 mm deep socket wrench, remove the water by-pass hose union from the cylinder block.
11. REMOVE OIL JET Remove the oil jet from the cylinder block.

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1. INSPECT CONNECTING ROD OIL CLEARANCE Clean the crank pin and connecting rod bearing. NOTE: Check the crank pin and connecting rod bearing for pitting and scratches. Install the crankshaft See step 5 . Install the connecting rod bearing See step 7 . Install the connecting rod sub-assembly See step 9 . Lay a strip of Plastigage across the crank pin. TEXT IN ILLUSTRATION *1 Plastigage Install the connecting rod cap See step 9 . NOTE: Do not turn crankshaft. Remove the connecting rod cap See step 3 . Measure the Plastigage at its widest point. TEXT IN ILLUSTRATION *1 Plastigage Standard Oil Clearance 0.012 to 0.034 mm (0.000472 to 0.00134 in.) Maximum Oil Clearance 0.06 mm (0.00236 in.) NOTE: Completely remove the Plastigage. If the connecting rod oil clearance is greater than the maximum, select and replace the connecting rod bearings. If necessary, use an undersized connecting rod bearing. TEXT IN ILLUSTRATION *a Number Mark *b Front Mark Reference Number Mark Connecting Rod External Diameter Center Bearing Thickness Oil Clearance 1 43.000 to 43.006 mm (1.6929 to 1.6931 in.) 1.491 to 1.494 mm (0.058701 to 0.058818 in.) 0.012 to 0.032 mm (0.000472 to 0.00125 in.) 2 43.006 to 43.014 mm (1.6931 to 1.6935 in.) 1.494 to 1.497 mm (0.058818 to 0.058937in.) 0.012 to 0.034 mm (0.000472 to 0.00134 in.) 3 43.014 to 43.020 mm (1.6935 to 1.6937 in.) 1.497 to 1.500 mm (0.058937 to 0.059055 in.) 0.014 to 0.034 mm (0.000551 to 0.00134 in.) U/S 0.25 43.000 to 43.020 mm (1.6929 to 1.6937 in.) 1.610 to 1.614 mm (0.063386 to 0.063543 in.) 0.012 to 0.034 mm (0.000472 to 0.00134 in.)
2. INSPECT CRANKSHAFT OIL CLEARANCE Clean the crank journal and crankshaft bearing cap. Install the crankshaft bearing See step 3 . Install the crankshaft See step 5 . Lay a strip of Plastigage across each journal. TEXT IN ILLUSTRATION *1 Plastigage Install the crankshaft bearing cap See step 5 . NOTE: Do not turn crankshaft. Remove the crankshaft bearing cap See step 7 . Measure the Plastigage at its widest point. TEXT IN ILLUSTRATION *1 Plastigage Standard Oil Clearance 0.010 to 0.026 mm (0.000394 to 0.00102 in.) Maximum Oil Clearance 0.07 mm (0.00276 in.) NOTE: Completely remove the Plastigage. If the crankshaft oil clearance is greater than the maximum, select and replace the crankshaft bearing. If necessary, use an undersized main bearing. TEXT IN ILLUSTRATION *a Cylinder Block Number *b Bearing Number *c Crank Journal Number HINT: To select the correct main bearing size, calculate the crankshaft bearing number by adding together the numbers imprinted on the cylinder block and crankshaft. Number on the cylinder block is 3. Number on the crankshaft is 5. 3 + 5 = 8 Select bearing number 3. Reference Number Cylinder Block Diameter Crankshaft Journal Diameter 0 50.000 to 50.003 mm (1.9685 to 1.9686 in.) 45.998 to 46.000 mm (1.8109 to 1.8110 in.) 1 50.003 to 50.005 mm (1.9686 to 1.9687 in.) 45.996 to 45.998 mm (1.81086 to 1.81094 in.) 2 50.005 to 50.007 mm (1.9687 to 1.9688 in.) 45.994 to 45.996 mm (1.8108 to 1.8109 in.) 3 50.007 to 50.010 mm (1.9688 to 1.9689 in.) 45.992 to 45.994 mm (1.8107 to 1.8108 in.) 4 50.010 to 50.012 mm (1.9689 to 1.9690 in.) 45.990 to 45.992 mm (1.8106 to 1.8107 in.) 5 50.012 to 50.014 mm (1.9690 to 1.9691 in.) 45.988 to 45.990 mm (1.8105 to 1.8106 in.) 6 50.014 to 50.016 mm (1.96905 to 1.96913 in.) - Reference Cylinder Block Number + Crank Journal Number Bearing Number Center Bearing Thickness Oil Clearance 0 to 2 1 1.992 to 1.995 mm (0.0784 to 0.0785 in.) 0.010 to 0.026 mm (0.000394 to 0.00102 in.) 3 to 5 2 1.995 to 1.998 mm (0.0785 to 0.0787 in.) 0.010 to 0.026 mm (0.000394 to 0.00102 in.) 6 to 8 3 1.998 to 2.001 mm (0.0787 to 0.0788 in.) 0.010 to 0.026 mm (0.000394 to 0.00102 in.) 9 to 11 4 2.001 to 2.004 mm (0.0788 to 0.0789 in.) 0.010 to 0.026 mm (0.000394 to 0.00102 in.) - U/S 0.25 2.111 to 2.117 mm (0.0831 to 0.0833 in.) 0.010 to 0.026 mm (0.000394 to 0.00102 in.)
3. INSPECT CYLINDER BLOCK FOR WARPAGE Using a precision straightedge and feeler gauge, check the cylinder block surface that contacts the cylinder head gasket for warpage. Maximum Warpage 0.05 mm (0.00197 in.) If the warpage is greater than the maximum, replace the cylinder block.
4. INSPECT CYLINDER BORE Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions. TEXT IN ILLUSTRATION *a Thrust Direction *b Axial Direction *c Center *d 10 mm (0.394 in.) Engine Front Standard Diameter 75.000 to 75.013 mm (2.9528 to 2.9533 in.) Maximum Diameter 75.133 mm (2.9580 in.) If the average diameter of the 4 positions is greater than the maximum, replace the cylinder block.
5. INSPECT CONNECTING ROD SUB-ASSEMBLY Using a caliper gauge, measure the inside diameter of the connecting rod sub-assembly. Standard Connecting Rod Inside Diameter 17.965 to 17.985 mm (0.707 to 0.708 in.) If the diameter is not as specified, replace the connecting rod sub-assembly. Using a connecting rod aligner and feeler gauge, check the connecting rod sub-assembly alignment. Check for misalignment. Maximum Misalignment 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If the misalignment is greater than the maximum, replace the connecting rod sub-assembly. Check for twist. Maximum Twist 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If the twist is greater than the maximum, replace the connecting rod sub-assembly.
6. INSPECT PISTON SUB-ASSEMBLY AND PISTON PIN Clean the piston sub-assembly and piston pin. Using a micrometer, measure the piston diameter at right angles to the piston pin hole, and at a point 37 mm (1.46 in.) from the piston bottom. TEXT IN ILLUSTRATION *a 37 mm (1.46 in.) Standard Piston Diameter 74.969 to 74.991 mm (2.9515 to 2.9524 in.) If the diameter is not as specified, replace the piston sub-assembly and piston pin. Using a caliper gauge, measure the piston pin hole diameter of the piston. Standard Piston Pin Hole Diameter 18.013 to 18.016 mm (0.70917 to 0.70929 in.) at 20°C (68°F) If the diameter is not as specified, replace the piston sub-assembly and piston pin. Using a micrometer, measure the piston pin diameter. Standard Piston Pin Diameter 18.001 to 18.004 mm (0.70870 to 0.70881 in.) Subtract the piston pin diameter measurement from the piston pin hole diameter measurement. Standard Oil Clearance 0.009 to 0.015 mm (0.000354 to 0.000591 in.) Maximum Oil Clearance 0.05 mm (0.00197 in.) If the oil clearance is greater than the maximum, replace the piston sub-assembly and piston pin.
7. INSPECT PISTON OIL CLEARANCE Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard Oil Clearance 0.009 to 0.044 mm (0.000354 to 0.00173 in.) Maximum Oil Clearance 0.08 mm (0.00315 in.) If the oil clearance is greater than the maximum, replace all the piston sub-assemblies and piston pins. If necessary, replace the cylinder block.
8. INSPECT RING GROOVE CLEARANCE Using a feeler gauge, measure the ring groove clearance between a new piston ring and the wall of the ring groove. Standard Ring Groove Clearance Item Specified Condition No. 1 ring 0.02 to 0.07 mm (0.000787 to 0.00276 in.) No. 2 ring 0.02 to 0.06 mm (0.000787 to 0.00236 in.) Oil ring 0.07 to 0.13 mm (0.00276 to 0.00512 in.) If the ring groove clearance is not as specified, replace the piston sub-assembly and piston pin.
9. INSPECT PISTON RING END GAP Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block. TEXT IN ILLUSTRATION *a 110 mm (4.33 in.) Using a feeler gauge, measure the ring end gap. Standard Ring End Gap Item Standard Maximum No. 1 ring 0.18 to 0.28 mm (0.00709 to 0.0110 in.) 0.59 mm (0.0232 in.) No. 2 ring 0.28 to 0.43 mm (0.0110 to 0.0169 in.) 1.18 mm (0.0465 in.) Oil ring 0.10 to 0.35 mm (0.00394 to 0.0138 in.) 1.13 mm (0.0445 in.) If the ring end gap is greater than the maximum, replace the piston ring and oil ring.
10. INSPECT CONNECTING ROD BOLT Using a vernier caliper, measure the diameter of the connecting rod bolt in the area shown in the illustration. TEXT IN ILLUSTRATION *a Measurement Area Standard Diameter 6.6 to 6.7 mm (0.260 to 0.264 in.) Minimum Diameter 6.4 mm (0.252 in.) If the diameter is less than the minimum, replace the connecting rod bolt.
11. INSPECT CRANKSHAFT Using a dial indicator and V-blocks, measure the runout as shown in the illustration. Maximum Runout 0.03 mm (0.00118 in.) If the runout is greater than the maximum, replace the crankshaft. Inspect the diameter. Using a micrometer, measure the diameter of each main journal as shown in the illustration. Standard Diameter 45.988 to 46.000 mm (1.8105 to 1.8110 in.) If the diameter is not as specified, replace the crankshaft. Calculate the taper and out-of-round of the main journal. Maximum Taper and Out-of-round 0.02 mm (0.000787 in.) If the taper or out-of-round is greater than the maximum, replace the crankshaft. Using a micrometer, measure the diameter of each crank pin as shown in the illustration. Standard Diameter 39.992 to 40.000 mm (1.5745 to 1.5748 in.) If the diameter is not as specified, replace the crankshaft. Calculate the taper and out-of-round of the crank pin. Maximum Taper and Out-of-round 0.02 mm (0.000787 in.) If the taper or out-of-round is greater than the maximum, replace the crankshaft. Wrap the chain sub-assembly around the timing sprocket. Using a vernier caliper, measure the diameter of the timing sprocket with the chain sub-assembly. Standard Sprocket Diameter 51.72 mm (2.04 in.) Minimum Sprocket Diameter 50.5 mm (1.99 in.) NOTE: When measuring the diameter, the vernier caliper must be in contact with the chain rollers. If the diameter is less than the minimum, replace the chain sub-assembly and crankshaft.
12. INSPECT CRANKSHAFT BEARING CAP SET BOLT Using a vernier caliper, measure the diameter of the crankshaft bearing cap set bolt at the thinnest point. Standard Diameter 7.3 to 7.5 mm (0.287 to 0.295 in.) Minimum Diameter 7.3 mm (0.287 in.) If the diameter is less than the minimum, replace the crankshaft bearing cap set bolt.

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1. REPLACE STUD BOLT HINT: If any of the stud bolts is deformed or the threads are damaged, replace it. Using an E8 "TORX" socket wrench, replace the stud bolts. TEXT IN ILLUSTRATION *a 12.0 mm (0.472 in.) *b 52.0 mm (2.05 in.) Torque: 6.5 N*m (66 kgf*cm, 58 in.*lbf)
2. REPLACE RING PIN HINT: If a ring pin is deformed or the threads are damaged, replace it. Remove the ring pins. Using a plastic hammer, tap in the ring pins to the specified protrusion height. TEXT IN ILLUSTRATION *a 8.0 mm (0.315 in.) *b 3.5 to 4.5 mm (0.138 to 0.177in.)
3. REPLACE STRAIGHT PIN HINT: If a straight pin is deformed or the threads are damaged, replace it. Remove the straight pins. Using a plastic hammer, tap in the straight pins to the specified protrusion height. TEXT IN ILLUSTRATION *a Timing Chain Cover Side *b Hybrid Vehicle Transaxle Side *c Cylinder Head Side *d Oil Pan Side *e 36.0 mm (1.42 in.) *f 10.0 mm (0.394 in.) *g 18.5 to 19.5 mm (0.728 to 0.768 in.) *h 22.0 mm (0.866 in.) *i 11.5 to 12.5 mm (0.453 to 0.492 in.) *j 18.0 mm (0.709 in.) *k 8.0 mm (0.315 in.) *l 8.5 to 9.5 mm (0.335 to 0.374 in.)

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1. INSTALL OIL JET Align the concave part of the cylinder block with the bracket of a new oil jet, then tap in the oil jet (the service part). TEXT IN ILLUSTRATION *a Align NOTE: Do not tap the tip of the oil jet.
2. INSTALL WATER BY-PASS HOSE UNION Apply adhesive as shown in the illustration. TEXT IN ILLUSTRATION *a 6.0 mm (0.236 in.) Adhesive Toyota genuine adhesive 1324, three bond 1324 or equivalent Using a 17 mm deep socket wrench, install the water by-pass hose union to the cylinder block. Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf) NOTE: Install the water by-pass hose union within 3 minutes of applying adhesive. Do not add coolant for at least 1 hour after installation.
3. INSTALL CRANKSHAFT BEARING Clean the main journal and both surfaces of the crankshaft bearing. Mass production parts do not have claws if reusing mass production parts, measure the clearance of both sides with the crankshaft bearings in the center of the crankshaft bearing caps. TEXT IN ILLUSTRATION *a Mass Production Part *b Claw *c Service Part Install the upper crankshaft bearing to the cylinder block as shown in the illustration. TEXT IN ILLUSTRATION *a CORRECT *b INCORRECT NOTE: Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the upper crankshaft bearing. The amount visible on each side of the holes should be equal. Do not apply engine oil to the bearings or their contact surfaces. Install the lower crankshaft bearing onto the crankshaft bearing cap. NOTE: Do not apply engine oil to the bearings and the contact surfaces. Using a vernier caliper, measure the distance between the crankshaft bearing caps edge and the lower crankshaft bearings edge. TEXT IN ILLUSTRATION *1 Vernier Caliper Standard dimension A - B or B - A 0 to 0.7 mm (0 to 0.0276 in.)
4. INSTALL UPPER CRANKSHAFT THRUST WASHER Install the 2 upper crankshaft thrust washers onto the No. 3 journal position of the cylinder block with the oil grooves facing outward. TEXT IN ILLUSTRATION *a Oil Groove
5. INSTALL CRANKSHAFT HINT: The crankshaft bearing cap bolts are tightened in 2 progressive steps. Apply engine oil to the upper crankshaft bearings and install the crankshaft onto the cylinder block. Check the front marks and numbers and install the crankshaft bearing caps onto the cylinder block. TEXT IN ILLUSTRATION *a Front Mark *b Number *c Front Mark and Number Apply a light coat of engine oil to the lower crankshaft bearings and threads of the crankshaft bearing cap bolts. Step 1: Using several steps, uniformly tighten and install the 10 crankshaft bearing cap bolts with 12 mm socket wrench for 12 pointed head in the sequence shown in the illustration. Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) Step 2: Mark each crankshaft bearing cap bolts head with a paint mark as shown in the illustration. TEXT IN ILLUSTRATION *a Paint Mark Engine Front Tighten the crankshaft bearing cap bolts 90° in the sequence shown in step 1. Check that the paint mark is now at a 90° angle to the front. Check that the crankshaft turns smoothly.
6. INSTALL PISTON SUB-ASSEMBLY WITH PISTON PIN HINT: Perform "Inspection After Repairs" after replacing the piston sub-assembly. Refer to «INITIALIZATION»(/toyota/prius-c/i-2011-2015/remont/testing-diagnostics/#engine-control-system-diagnostics-introduction) . Gradually heat the connecting rod up to 80 to 90°C (176 to 194°F). Apply engine oil to the piston pin and the inside surface of the connecting rod sub-assembly. Align the front marks of the piston sub-assembly and connecting rod sub-assembly. TEXT IN ILLUSTRATION *a Front Mark Using SST, push in the piston pin. TEXT IN ILLUSTRATION *1 Piston Pin *2 Connecting Rod Sub-assembly *3 Piston Sub-assembly *a Press *b 1.25 to 2.25 mm (0.0492 to 0.0886 in.) SST: 09221-25026 09221-00021 09221-00030 09221-00061 09221-00090 09221-00100 NOTE: The piston sub-assembly and piston pin are a matched set. With the connecting rod fully inserted into the piston end, press in the piston pin until it is flush with the piston surface. Check the fitting condition between the piston sub-assembly and piston pin by trying to move the piston back and forth on the piston pin.
7. INSTALL CONNECTING ROD BEARING Align the connecting rod bearing claw with the grooves of the connecting rod and connecting rod cap. TEXT IN ILLUSTRATION *a Claw NOTE: Do not apply engine oil to the contact surface of the connecting rod and connecting rod cap or the backside of the connecting rod bearing.
8. INSTALL PISTON RING SET HINT: Perform "Inspection After Repairs" after replacing the piston ring. Refer to «INITIALIZATION»(/toyota/prius-c/i-2011-2015/remont/testing-diagnostics/#engine-control-system-diagnostics-introduction) . Install the oil ring expander and oil ring by hand. TEXT IN ILLUSTRATION *1 Oil Ring *2 Oil Ring Expander *a Oil Ring Expander Joint *b Oil Ring Ends Using a piston ring expander, install the No. 2 compression ring as shown in the illustration. TEXT IN ILLUSTRATION *a Code Mark *b Paint Mark Up PISTON RING MARK Part Paint Mark Code Mark No. 2 compression ring Blue 2R NOTE: Install the No. 2 compression ring with the code mark facing upward. Using a piston ring expander, install the No. 1 compression ring as shown in the illustration. TEXT IN ILLUSTRATION *a Compression Ring Ends *b Paint Mark PISTON RING MARK Part Paint Mark Code Mark No. 1 compression ring Red - NOTE: Place a paint mark on the right side of the opening. Position the piston rings so that the ring ends are as shown in the illustration. TEXT IN ILLUSTRATION *1 No. 1 Compression Ring *2 Oil Ring *3 No. 2 Compression Ring *a Front Mark Engine Front
9. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD HINT: The connecting rod cap bolts are tightened in 2 progressive steps. Apply engine oil to the cylinder walls, pistons, and surfaces of the connecting rod bearings. NOTE: Do not apply engine oil to the contact surface of the connecting rod and connecting rod cap or the backside of the connecting rod bearing. Check the position of the piston ring ends. Using a piston ring compressor, push the correct piston sub-assembly and connecting rod sub-assembly into each cylinder with the front mark on the piston facing forward. TEXT IN ILLUSTRATION *1 Piston Ring Compressor *a Front Mark Check that the front mark of the connecting rod cap is facing forward and install the connecting rod cap. TEXT IN ILLUSTRATION *a Front Mark Apply a light coat of engine oil to the threads of the connecting rod cap bolts. Step 1: Using SST, install and alternately tighten the connecting rod cap bolts of the connecting rod cap in several steps. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) SST: 09205-16010 Step 2: Mark each connecting rod cap bolts head with a paint mark as shown in the illustration. TEXT IN ILLUSTRATION *a Paint Mark Engine Front Tighten the connecting rod cap bolts 90° in the sequence shown in step 1. Check that the paint mark is now at a 90° angle to the front. Check that the crankshaft turns smoothly.

See also:
• ON-VEHICLE INSPECTION
• ON-VEHICLE INSPECTION
• ON-VEHICLE INSPECTION
• ON-VEHICLE INSPECTION
• INSPECTION MODE PROCEDURE
• REMOVAL
• DTC CHECK / CLEAR
• REMOVAL
• REMOVAL - Step 12
• INITIALIZATION
• REMOVAL - Step 5
• REMOVAL
• REPLACEMENT - Step 1
• PRECAUTION
• REMOVAL
• REMOVAL
• REPLACEMENT - Step 1
• REMOVAL
• REMOVAL - Step 4
• REMOVAL
• REMOVAL - Step 10
• REMOVAL - Step 2
• REMOVAL - Step 9
• REMOVAL
• INSTALLATION
• INSTALLATION
• INSTALLATION
• INSTALLATION
• ON-VEHICLE INSPECTION - Step 1
• ADJUSTMENT
• TEST MODE PROCEDURE
• ADJUSTMENT
• REMOVAL
• INSTALLATION