Engine Mechanical (service Specifications) — Toyota Prius C I (2011-2015)

SERVICE DATA

Ignition timing	Terminals TC and CG of DLC3 connected	8 to 12° BTDC at idle (Transmission in neutral)
Ignition timing	Terminals TC and CG of DLC3 disconnected	12 to 16° BTDC at idle (Transmission in neutral)
Idle speed		950 to 1050 rpm (Transmission in neutral)
Compression	Compression pressure	871 kPa (8.9 kgf/cm 2 , 126 psi)
	Minimum pressure	661 kPa (6.7 kgf/cm 2 , 96 psi)
	Difference between each cylinder	100 kPa (1.0 kgf/cm 2 , 15 psi)

ENGINE

Valve clearance (cold) (No. 1 cylinder TDC/compression)	Intake	Standard	0.15 to 0.25 mm (0.00591 to 0.0984 in.)
Valve clearance (cold) (No. 1 cylinder TDC/compression)	Exhaust	Standard	0.25 to 0.35 mm (0.00984 to 0.0138 in.)
Valve clearance (cold) (No. 4 cylinder TDC/compression)	Intake	Standard	0.15 to 0.25 mm (0.00591 to 0.0984 in.)
Valve clearance (cold) (No. 4 cylinder TDC/compression)	Exhaust	Standard	0.25 to 0.35 mm (0.00984 to 0.0138 in.)

VALVE CLEARANCE

Chain sub-assembly	Length	Maximum	124.2 mm (4.89 in.)
Camshaft timing gear assembly	Diameter (with chain)	Minimum	96.2 mm (3.79 in.)
Camshaft timing sprocket	Diameter (with chain)	Minimum	96.2 mm (3.79 in.)
Chain tensioner slipper	Wear	Maximum	1.0 mm (0.0394 in.)
No. 1 chain vibration damper	Wear	Maximum	1.0 mm (0.0394 in.)
Cylinder head set bolt length		Standard	142.8 to 144.2 mm (5.62 to 5.68 in.)
Cylinder head set bolt length		Maximum	147.1 mm (5.79 in.)
Exhaust manifold	Warpage	Maximum	0.70 mm (0.0276 in.)

ENGINE UNIT

Cylinder head for flatness	Cylinder block side	Maximum	0.05 mm (0.00197 in.)
	Intake manifold side	Maximum	0.10 mm (0.00394 in.)
	Exhaust manifold side	Maximum	0.10 mm (0.00394 in.)
Compression spring	Free length	Standard	59.77 mm (2.35 in.)
Compression spring	Deviation	Maximum	1.6 mm (0.0630 in.)
Intake valve	Overall length	Standard	89.25 mm (3.51 in.)
	Overall length	Minimum	88.95 mm (3.50 in.)
	Valve stem diameter	Standard	4.970 to 4.985 mm (0.19567 to 0.19626 in.)
	Margin thickness	Standard	1.0 mm (0.0394 in.)
	Margin thickness	Minimum	0.7 mm (0.0276 in.)
Exhaust valve	Overall length	Standard	87.90 mm (3.46 in.)
	Overall length	Minimum	87.60 mm (3.45 in.)
	Valve stem diameter	Standard	4.965 to 4.980 mm (0.19547 to 0.19606 in.)
	Margin thickness	Standard	1.15 mm (0.0453 in.)
	Margin thickness	Minimum	0.85 mm (0.0335 in.)
Intake valve guide bush	Inside diameter	Standard	5.01 to 5.03 mm (0.197 to 0.198 in.)
	Oil clearance	Standard	0.025 to 0.060 mm (0.000984 to 0.00236 in.)
	Oil clearance	Minimum	0.080 mm (0.00315 in.)
	Bush bore diameter	Use STD	9.685 to 9.706 mm (0.381 to 0.382 in.)
	Bush bore diameter	Use O/S 0.05	9.735 to 9.756 mm (0.383 to 0.384 in.)
	Protrusion height		9.0 to 9.4 mm (0.354 to 0.370 in.)
Exhaust valve guide bush	Bush inside diameter	Standard	5.01 to 5.03 mm (0.197 to 0.198 in.)
	Oil clearance	Standard	0.030 to 0.065 mm (0.00118 to 0.00256 in.)
	Oil clearance	Minimum	0.10 mm (0.00394 in.)
	Bush bore diameter	Standard	9.685 to 9.706 mm (0.381 to 0.382 in.)
	Bush bore diameter	O/S 0.05	9.735 to 9.756 mm (0.383 to 0.384 in.)
	Protrusion height		9.0 to 9.4 mm (0.354 to 0.370 in.)
Valve lifter	Diameter	Standard	30.966 to 30.976 mm (1.2191 to 1.2195 in.)
	Bore diameter	Standard	31.009 to 31.025 mm (1.2208 to 1.2215 in.)
	Oil clearance	Standard	0.033 to 0.059 mm (0.00130 to 0.00232 in.)
	Oil clearance	Maximum	0.1 mm (0.00394 in.)
Camshaft	Circle runout	Minimum	0.03 mm (0.00118 in.)
	Cam lobe height	Standard	42.261 to 42.461 mm (1.6638 to 1.6717 in.)
	Cam lobe height	Maximum	42.16 mm (1.6598 in.)
	No. 1 journal diameter	Standard	34.449 to 34.465 mm (1.3563 to 1.3569 in.)
	Other journal diameter	Standard	22.949 to 22.965 mm (0.90350 to 0.90413 in.)
No. 2 Camshaft	Circle runout	Minimum	0.03 mm (0.00118 in.)
	Cam lobe height	Standard	44.046 to 44.146 (1.7341 to 1.7380 in.)
	Cam lobe height	Minimum	43.90 mm (1.7283 in.)
	No. 1 journal diameter	Standard	34.449 to 34.465 mm (1.3563 to 1.3569 in.)
	Other journal diameter	Standard	22.949 to 22.965 mm (0.90350 to 0.90413 in.)
Camshaft thrust clearance		Standard	0.040 to 0.095 mm (0.00157 to 0.00374 in.)
Camshaft thrust clearance		Maximum	0.110 mm (0.00433 in.)
Camshaft oil clearance		Standard	0.035 to 0.072 mm (0.00138 to 0.00283 in.)
Camshaft oil clearance		Maximum	0.115 mm (0.00453 in.)

CYLINDER HEAD

Connecting rod
Connecting rod thrust clearance		Standard	0.16 to 0.36 mm (0.00630 to 0.0142 in.)
Connecting rod thrust clearance		Maximum	0.36 mm (0.0142 in.)
Connecting rod oil clearance		Standard	0.012 to 0.034 mm (0.000472 to 0.00134 in.)
		U/S 0.25	0.012 to 0.034 mm (0.000472 to 0.00134 in.)
		Maximum	0.06 mm (0.00236 in.)
Connecting rod external diameter		Mark 1	43.000 to 43.006 mm (1.6929 to 1.6931 in.)
		Mark 2	43.006 to 43.014 mm (1.6931 to 1.6935 in.)
		Mark 3	43.014 to 43.020 mm (1.6935 to 1.6937 in.)
		U/S 0.25	43.000 to 43.020 mm (1.6929 to 1.6937 in.)
Center bearing thickness		Mark 1	1.491 to 1.494 mm (0.058701 to 0.058818 in.)
		Mark 2	1.494 to 1.497 mm (0.058818 to 0.058937 in.)
		Mark 3	1.497 to 1.500 mm (0.058937 to 0.059055 in.)
		U/S 0.25	1.610 to 1.614 mm (0.063386 to 0.063543 in.)
Connecting rod small end bore diameter		Standard	17.965 to 17.985 mm (0.707 to 0.708 in.)
Maximum rod misalignment per 100 mm (3.94 in.)			0.05 mm (0.00197 in.)
Maximum rod twist per 100 mm (3.94 in.)			0.05 mm (0.00197 in.)
Cylinder block
Cylinder block warpage		Maximum	0.05 mm (0.00197 in.)
Cylinder bore diameter		Standard	75.000 to 75.013 mm (2.9528 to 2.9533 in.)
Cylinder bore diameter		Maximum	75.133 mm (2.9580 in.)
Piston
Piston diameter		Standard	74.969 to 74.991 mm (2.9515 to 2.9524 in.)
Piston oil clearance		Standard	0.009 to 0.044 mm (0.000354 to 0.00173 in.)
Piston oil clearance		Maximum	0.08 mm (0.00315 in.)
Piston pin hole diameter		Standard	18.013 to 18.016 mm (0.70917 to 0.70929 in.) at 20°C (68°F)
Piston ring
Piston ring groove clearance	No. 1 Ring	Standard	0.02 to 0.07 mm (0.000787 to 0.00276 in.)
	No. 2 Ring	Standard	0.02 to 0.06 mm (0.000787 to 0.00236 in.)
	Oil Ring	Standard	0.07 to 0.13 mm (0.00276 to 0.00512 in.)
Piston ring end gap	No. 1 Ring	Standard	0.18 to 0.28 mm (0.00709 to 0.0110 in.)
	No. 1 Ring	Maximum	0.59 mm (0.0232 in.)
	No. 2 Ring	Standard	0.28 to 0.43 mm (0.0110 to 0.0169 in.)
	No. 2 Ring	Maximum	1.18 mm (0.0465 in.)
	Oil Ring	Standard	0.10 to 0.35 mm (0.00394 to 0.0138 in.)
	Oil Ring	Maximum	1.13 mm (0.0445 in.)
Piston pin
Piston pin diameter		Standard	18.001 to 18.004 mm (0.70870 to 0.70881 in.)
Piston pin oil clearance		Standard	0.009 to 0.015 mm (0.000354 to 0.000591 in.)
Piston pin oil clearance		Maximum	0.05 mm (0.00197 in.)
Connecting rod bolt diameter		Standard	6.6 to 6.7 mm (0.260 to 0.264 in.)
Connecting rod bolt diameter		Maximum	6.4 mm (0.252 in.)
Crankshaft
Crankshaft circle runout		Maximum	0.03 mm (0.00118 in.)
Crankshaft main journal diameter		Standard	45.988 to 46.000 mm (1.8105 to 1.8110 in.)
Crankshaft main journal diameter		Maximum taper and distortion	0.02 mm (0.000787 in.)
Crank pin diameter		Standard	39.992 to 40.000 mm (1.5745 to 1.5748 in.)
Crank pin diameter		Maximum taper and distortion	0.02 mm (0.000787 in.)
Crankshaft timing sprocket	Diameter (with chain)	Maximum	50.5 mm (1.99 in.)
Crankshaft thrust clearance		Standard	0.04 to 0.24 mm (0.00157 to 0.00945 in.)
Crankshaft thrust clearance		Maximum	0.3 mm (0.0118 in.)
Thrust washer thickness		Standard	2.43 to 2.48 mm (0.0957 to 0.0976 in.)
		O/S 0.125	2.493 to 2.543 (0.0981 to 0.100 in.)
		O/S 0.250	2.555 to 2.605 (0.101 to 0.103 in.)
Cylinder block main journal bore diameter (Reference)		Mark 0	50.000 to 50.003 mm (1.9685 to 1.9686 in.)
		Mark 1	50.003 to 50.005 mm (1.9686 to 1.9687 in.)
		Mark 2	50.005 to 50.007 mm (1.9687 to 1.9688 in.)
		Mark 3	50.007 to 50.010 mm (1.9688 to 1.9689 in.)
		Mark 4	50.010 to 50.012 mm (1.9689 to 1.9690 in.)
		Mark 5	50.012 to 50.014 mm (1.9690 to 1.9691 in.)
		Mark 6	50.014 to 50.016 mm (1.96905 to 1.96913 in.)
Main journal diameter (Reference)		Mark 0	45.998 to 46.000 mm (1.8109 to 1.8110 in.)
		Mark 1	45.996 to 45.998 mm (1.81086 to 1.81094 in.)
		Mark 2	45.994 to 45.996 mm (1.8108 to 1.8109 in.)
		Mark 3	45.992 to 45.994 mm (1.8107 to 1.8108 in.)
		Mark 4	45.990 to 45.992 mm (1.8106 to 1.8107 in.)
		Mark 5	45.988 to 45.990 mm (1.8105 to 1.8106 in.)
Main bearing center wall thickness (Reference)		Mark 1	1.992 to 1.995 mm (0.0784 to 0.0785 in.)
		Mark 2	1.995 to 1.998 mm (0.0785 to 0.0787 in.)
		Mark 3	1.998 to 2.001 mm (0.0787 to 0.0788 in.)
		Mark 4	2.001 to 2.004 mm (0.0788 to 0.0789 in.)
		U/S 0.25	2.111 to 2.117 mm (0.0831 to 0.0834 in.)
Crankshaft oil clearance		Standard	0.010 to 0.026 mm (0.000394 to 0.00102 in.)
Crankshaft oil clearance		Maximum	0.07 mm (0.00276 in.)
Crankshaft bearing cap set bolt diameter		Standard	7.3 to 7.5 mm (0.287 to 0.295 in.)
Crankshaft bearing cap set bolt diameter		Minimum	7.3 mm (0.287 in.)

CYLINDER BLOCK

CAMSHAFT

Part Tightened	N*m	Kgf*cm	Ft.*lbf
Camshaft timing gear assembly x Camshaft	64	652	47
Camshaft timing gear or sprocket x No. 2 camshaft	64	652	47
No. 1 camshaft bearing cap x Cylinder head sub-assembly	23	234	17
No. 2 camshaft bearing cap x Cylinder head sub-assembly	13	129	9
Cylinder head cover sub-assembly x Cylinder head sub-assembly	13	132	10
Engine wire x Cylinder head cover sub-assembly	8.4	85	74 in.*lbf
Brake master cylinder reservoir assembly x Body	8.0	82	71 in.*lbf

CAMSHAFT

CYLINDER HEAD GASKET

Part Tightened		N*m	Kgf*cm	Ft.*lbf
Cylinder head sub-assembly x Cylinder block	1st	29	300	22
	2nd	Turn 90°	Turn 90°	Turn 90°
	3rd	Turn 90°	Turn 90°	Turn 90°
No. 1 camshaft bearing cap x Cylinder head sub-assembly		23	234	17
No. 2 camshaft bearing cap x Cylinder head sub-assembly		13	129	9
No. 1 chain vibration damper x Cylinder block		9.0	92	80 in.*lbf
No. 1 chain tensioner assembly x Cylinder block		9.0	92	80 in.*lbf

CYLINDER HEAD GASKET

FRONT CRANKSHAFT OIL SEAL

Part Tightened	N*m	Kgf*cm	Ft.*lbf
Crankshaft damper sub-assembly x Crankshaft	128	1305	94
Engine mounting insulator sub-assembly RH x Body and Engine assembly	52	530	38
Engine room relay block and junction block assembly x Body	5.4	55	48

FRONT CRANKSHAFT OIL SEAL

REAR CRANKSHAFT OIL SEAL

Part Tightened		N*m	Kgf*cm	Ft.*lbf
Flywheel sub-assembly x Crankshaft		83	846	61
Transmission input damper assembly x Flywheel sub-assembly		25	255	18

REAR CRANKSHAFT OIL SEAL

ENGINE ASSEMBLY

Part Tightened		N*m	Kgf*cm	Ft.*lbf
Engine mounting insulator LH x Body and Engine assembly		52	530	38
Engine mounting insulator RH sub-assembly x Body and Engine assembly		52	530	38
Hybrid vehicle transaxle assembly x Engine assembly	For hybrid vehicle transaxle assembly side	64	653	47
Hybrid vehicle transaxle assembly x Engine assembly	For engine assembly side	30	301	22
Starter hole insulator x Engine assembly		30	301	22
Drive shaft heat insulator bracket x Engine assembly		30	301	22
Drive shaft heat insulator sub-assembly x Drive shaft heat insulator bracket		18	179	13
Wire harness clamp bracket x Hybrid vehicle transaxle assembly		13	130	9
Transmission control cable clamp x Hybrid vehicle transaxle assembly		12	122	9
Front suspension crossmember x Body	Bolt A	87	887	64
	Bolt B	151	1539	111
	Bolt C	98	999	72
Transmission control cable x Transmission control shaft lever		12	122	9
Inverter bracket assembly x Hybrid vehicle transaxle assembly		21	214	15
Earth wire x Inverter bracket assembly		8.4	85	74 in.*lbf
Inverter reservoir tank assembly x Inverter bracket assembly		7.0	71	62 in.*lbf
Motor cable protector x Inverter bracket assembly		8.0	82	71 in.*lbf
No. 1 engine hanger x Engine assembly		44	448	32

ENGINE ASSEMBLY

ENGINE UNIT

Part Tightened		N*m	Kgf*cm	Ft.*lbf
Stud bolt x Oil pan sub-assembly		5.0	51	44 in.*lbf
Oil pan sub-assembly x Cylinder block		24	245	18
Oil strainer subassembly x Oil pan sub-assembly		13	132	10
No. 2 oil pan sub-assembly x Oil pan sub-assembly		9.0	92	80 in.*lbf
Oil pan drain plug x No. 2 oil pan sub-assembly		38	382	28
Oil filter union x Oil pan sub-assembly		30	306	22
Camshaft timing gear or sprocket x No. 2 camshaft		64	652	74
No. 1 camshaft bearing cap x Cylinder head sub-assembly		23	234	17
No. 2 camshaft bearing cap x Cylinder head sub-assembly		13	129	9
Crankshaft damper sub-assembly x Crankshaft		128	1305	94
Water inlet housing x Cylinder block		25	255	18
Water pump assembly x Water inlet housing		21	214	15
Water inlet with thermostat sub-assembly x Water inlet housing		10	102	7
Fuel delivery pipe x Cylinder head sub-assembly	Bolt A	21	214	15
Fuel delivery pipe x Cylinder head sub-assembly	Bolt B	10	102	7
Cylinder head cover sub-assembly x Cylinder head sub-assembly		13	132	10
Ventilation valve sub-assembly x Cylinder head cover subassembly		27	275	20
Oil pressure switch assembly x Cylinder block		15	153	11
Engine coolant temperature sensor x Cylinder head sub-assembly		20	204	15
Knock control sensor x Cylinder block		20	204	15
Crankshaft position sensor x Timing chain cover		7.5	76	66 in.*lbf
Camshaft timing oil control valve assembly x Cylinder head sub-assembly		7.5	76	66 in.*lbf
Camshaft position sensor x Cylinder head sub-assembly		8.0	82	71 in.*lbf
Stud bolt x Cylinder block		9.0	92	80 in.*lbf
Wire harness clamp bracket x Cylinder head cover sub-assembly		8.4	85	74 in.*lbf
No. 1 water by-pass pipe x Engine assembly		10	102	7
No. 4 water by-pass hose x Engine assembly		10	102	7

ENGINE UNIT

CYLINDER HEAD

Part Tightened		N*m	Kgf*cm	Ft.*lbf
Stud bolt x Cylinder head sub-assembly	Bolt A	10	102	7
	Bolt B	4.0	41	35 in.*lbf
	Bolt C	10	102	7
	Bolt D	9.0	92	80 in.*lbf
Straight screw plug x Cylinder head sub-assembly		30	306	22
Taper screw plug x Cylinder head sub-assembly		44	449	32

CYLINDER HEAD

CYLINDER BLOCK

Part Tightened		N*m	Kgf*cm	Ft.*lbf
Stud bolt x Cylinder block		6.5	66	58 in.*lbf
Water by-pass hose union x Cylinder block		35	357	26
Crankshaft bearing cap x Cylinder block	1nd	22	224	16
Crankshaft bearing cap x Cylinder block	2rd	Turn 90°	Turn 90°	Turn 90°
Connecting rod cap x Connecting rod	1st	15	153	11
Connecting rod cap x Connecting rod	2nd	Turn 90°	Turn 90°	Turn 90°

CYLINDER BLOCK

Engine Mechanical (service Specifications) Toyota Prius C I

SERVICE DATA

CAMSHAFT

CYLINDER HEAD GASKET

FRONT CRANKSHAFT OIL SEAL

REAR CRANKSHAFT OIL SEAL

ENGINE ASSEMBLY

ENGINE UNIT

CYLINDER HEAD

CYLINDER BLOCK

More articles — Engine

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