Engine Control System (Service Information) (Plug-In): Removal & Installation Toyota Prius Plug-in

INSTALLATION

1. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Apply a light coat of engine oil to a new O-ring and install it onto the camshaft timing oil control valve assembly. NOTE: Do not twist the O-ring. Install the camshaft timing oil control valve assembly and wire harness bracket with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the camshaft timing oil control valve assembly connector.
2. INSPECT FOR OIL LEAK
3. INSTALL NO. 2 CYLINDER HEAD COVER . Refer to «INSTALLATION - Step 99»(ref-553433-S18020678732013051700000)

Scheme 758

Scheme 759

1. INSTALL MASS AIR FLOW METER Install the mass air flow meter with the 2 screws. NOTE: Make sure that the O-ring is not cracked or does not jump out of position during installation. Connect the mass air flow meter connector.
2. INSTALL NO. 2 CYLINDER HEAD COVER . Refer to «INSTALLATION - Step 99»(ref-553433-S18020678732013051700000)

Scheme 760

REMOVAL

HINT

Although the part name refers to the No. 1 crank position sensors, this procedure is for the camshaft position sensors.

Scheme 761

1. REMOVE NO. 2 CYLINDER HEAD COVER . Refer to «REMOVAL - Step 29»(ref-553433-S31264435182013051700000)
2. REMOVE NO. 1 CRANK POSITION SENSOR Disconnect the No. 1 crank position sensor connector. Remove the bolt and No. 1 crank position sensor.

HINT

Although the part name refers to the No. 1 crank position sensors, this procedure is for the camshaft position sensors.

Scheme 762

1. INSTALL NO. 1 CRANK POSITION SENSOR Apply a light coat of engine oil to the O-rings on the No. 1 crank position sensors. Install the No. 1 crank position sensor with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the No. 1 crank position sensor connector.
2. INSPECT FOR OIL LEAK
3. INSTALL NO. 2 CYLINDER HEAD COVER . Refer to «INSTALLATION - Step 99»(ref-553433-S18020678732013051700000)

Scheme 763

Scheme 764

Scheme 765

Scheme 766

1. REMOVE REAR ENGINE UNDER COVER RH
2. REMOVE NO. 1 ENGINE UNDER COVER
3. REMOVE CRANK POSITION SENSOR Disconnect the crank position sensor connector. Remove the bolt and crank position sensor.

Scheme 767

1. INSPECT CRANK POSITION SENSOR Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *1 Ohmmeter Standard Resistance Tester Connection Condition Specified Condition 1 - 2 -10 to 50°C (14 to 122°F) 1850 to 2450 ohms

Scheme 768

1. INSTALL CRANK POSITION SENSOR Apply a light coat of engine oil to the O-ring on the crank position sensor. Install the crank position sensor with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the crank position sensor connector.
2. INSPECT FOR OIL LEAK
3. INSTALL NO. 1 ENGINE UNDER COVER
4. INSTALL REAR ENGINE UNDER COVER RH

Scheme 769

Scheme 770

Scheme 771

Scheme 772

1. REMOVE WINDSHIELD WIPER MOTOR AND LINK Remove the windshield wiper motor and link. Refer to «REMOVAL»(ref-553448-S42916831572013051700000) .
2. REMOVE COWL BODY MOUNTING REINFORCEMENT LH . Refer to «REMOVAL - Step 5»(ref-553419-S23117415602013051700000)
3. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to «REMOVAL - Step 6»(ref-553419-S23117415602013051700000)
4. REMOVE NO. 2 CYLINDER HEAD COVER . Refer to «REMOVAL - Step 29»(ref-553433-S31264435182013051700000)
5. REMOVE IGNITION COIL ASSEMBLY Disconnect the 4 ignition coil connectors. Remove the 4 bolts and 4 ignition coils. NOTE: When removing each ignition coil, do not damage the plug cap on the engine head cover opening or the upper edge of the spark plug tube.
6. REMOVE SPARK PLUG Using a 14 mm spark plug wrench, remove the 4 spark plugs.

1. INSTALL SPARK PLUG Using a 14 mm spark plug wrench, install the 4 spark plugs. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
2. INSTALL IGNITION COIL ASSEMBLY Install the 4 ignition coils with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE: When installing each ignition coil, do not damage the plug cap on the engine head cover opening or the upper edge of the spark plug tube. Connect the 4 ignition coil connectors.
3. INSTALL NO. 2 CYLINDER HEAD COVER . Refer to «INSTALLATION - Step 99»(ref-553433-S18020678732013051700000)
4. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to «INSTALLATION - Step 16»(ref-553419-S23239863982013051700000)
5. INSTALL COWL BODY MOUNTING REINFORCEMENT LH . Refer to «INSTALLATION - Step 17»(ref-553419-S23239863982013051700000)
6. INSTALL WINDSHIELD WIPER MOTOR AND LINK Remove the windshield wiper motor and link. Refer to «INSTALLATION»(ref-553448-S02112734502013051700000) .

Scheme 773

Scheme 774

1. DISCHARGE FUEL SYSTEM PRESSURE Refer to «PRECAUTION»(ref-553434-S25535887562013051700000) .
2. DRAIN COOLANT (for Engine) . Refer to «REPLACEMENT - Step 1»(ref-553423-S16600645432013051700000)
3. REMOVE FUEL INJECTOR ASSEMBLY Refer to «REMOVAL»(ref-553438-S38272280762013051700000) .
4. SEPARATE INVERTER RESERVE TANK ASSEMBLY See step 5
5. REMOVE ENGINE COOLANT TEMPERATURE SENSOR Disconnect the engine coolant temperature sensor connector. Using a union nut wrench 19 mm, remove the engine coolant temperature sensor. TEXT IN ILLUSTRATION *a Union Nut Wrench *b Gasket Remove the gasket from the engine coolant temperature sensor.

Scheme 775

1. INSPECT E.F.I. ENGINE COOLANT TEMPERATURE SENSOR Measure the resistance according to the value(s) in the table below. Standard Resistance Condition Specified Condition Approximately 20°C (68°F) 2.32 to 2.59 kohms Approximately 80°C (176°F) 0.310 to 0.326 kohms NOTE: When checking the engine coolant temperature sensor in water, keep the terminals dry. After the check, dry the sensor. If the resistance is not as specified, replace the engine coolant temperature sensor.

1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR Install a new gasket to the engine coolant temperature sensor. Using a union nut wrench 19 mm, install the engine coolant temperature sensor. Torque: 20 N*m (200 kgf*cm, 14 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»(ref-553290-S20522462032013051700000) . Connect the engine coolant temperature sensor connector.
2. INSTALL INVERTER RESERVE TANK ASSEMBLY See step 2
3. INSTALL FUEL INJECTOR ASSEMBLY Refer to «INSTALLATION»(ref-553438-S41904790712013051700000) .
4. ADD COOLANT (for Engine) . Refer to «REPLACEMENT - Step 2»(ref-553423-S16600645432013051700000)
5. INSPECT FOR COOLANT LEAK (for Engine) . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-553441-S40353769422013051700000)
6. INSPECT FOR FUEL LEAK . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-553434-S00186218912013051700000)

Scheme 776

Scheme 777

1. REMOVE INTAKE MANIFOLD Remove the intake manifold. Refer to «REMOVAL»(ref-553443-S18816749452013051700000) .
2. REMOVE KNOCK SENSOR Disconnect the knock sensor connector. Remove the bolt and remove the knock sensor.

Scheme 778

1. INSPECT KNOCK SENSOR TEXT IN ILLUSTRATION *1 Ohmmeter Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1 - 2 20°C (68°F) 120 to 280 kohms If the result is not as specified, replace the knock sensor.

Scheme 779

1. INSTALL KNOCK SENSOR Install the knock sensor with the bolt as shown in the illustration. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) NOTE: Make sure that the knock control sensor is in the correct position. Connect the knock sensor connector.
2. INSTALL INTAKE MANIFOLD Install the intake manifold. Refer to «INSTALLATION»(ref-553443-S30707450942013051700000) .

Scheme 780

Scheme 781

Scheme 782

1. REMOVE WINDSHIELD WIPER MOTOR AND LINK Remove the windshield wiper motor and link. Refer to «REMOVAL»(ref-553448-S42916831572013051700000) .
2. REMOVE COWL BODY MOUNTING REINFORCEMENT LH . Refer to «REMOVAL - Step 5»(ref-553419-S23117415602013051700000)
3. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to «REMOVAL - Step 6»(ref-553419-S23117415602013051700000)
4. REMOVE NO. 2 CYLINDER HEAD COVER . Refer to «REMOVAL - Step 29»(ref-553433-S31264435182013051700000)
5. REMOVE AIR FUEL RATIO SENSOR Disconnect the air fuel ratio sensor connector and clamp. Using SST, remove the air fuel ratio sensor. SST: 09224-00010

Scheme 783

1. INSPECT AIR FUEL RATIO SENSOR Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1 (HA1A) - 2 (+B) 20°C (68°F) 1.6 to 3.2 ohms 1 (HA1A) - 4 (A1A-) - 10 kohms or higher TEXT IN ILLUSTRATION *1 Ohmmeter If the result is not as specified, replace the air fuel ratio sensor.

Scheme 784

1. INSTALL AIR FUEL RATIO SENSOR Using SST, install the air fuel ratio sensor. SST: 09224-00010 without SST Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) with SST Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) NOTE: The "with SST" torque value is effective when using SST with a fulcrum length of 30 mm (1.18 in.) and a torque wrench with a fulcrum length of 260 mm (10.2 in.). Refer to «PRECAUTION»(ref-553290-S20522462032013051700000) . The "with SST" torque value is effective when SST is parallel to the torque wrench. Connect the air fuel ratio sensor connector and clamp.
2. INSTALL NO. 2 CYLINDER HEAD COVER . Refer to «INSTALLATION - Step 99»(ref-553433-S18020678732013051700000)
3. INSPECT FOR EXHAUST GAS LEAK
4. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to «INSTALLATION - Step 16»(ref-553419-S23239863982013051700000)
5. INSTALL COWL BODY MOUNTING REINFORCEMENT LH . Refer to «INSTALLATION - Step 17»(ref-553419-S23239863982013051700000)
6. INSTALL WINDSHIELD WIPER MOTOR AND LINK Install the windshield wiper motor and link. Refer to «INSTALLATION»(ref-553448-S02112734502013051700000) .

Scheme 785

Scheme 786

Scheme 787

Scheme 788

Scheme 789

1. REMOVE NO. 3 ENGINE UNDER COVER Remove the 4 clips and No. 3 engine under cover.
2. REMOVE HEATED OXYGEN SENSOR Disconnect the heated oxygen sensor connector. Remove the grommet and pull the sensor connector out of the cabin through the floor panel. Remove the wire harness clamp bracket and disconnect the wire harness clamp. Using SST, remove the heated oxygen sensor. SST: 09224-00010

Scheme 790

1. INSPECT HEATED OXYGEN SENSOR TEXT IN ILLUSTRATION *1 Component without harness connected (Heated Oxygen Sensor) Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition (HT) - (+B) 20°C (68°F) 11 to 16 ohms (HT) - (E) - 10 kohms or higher If the result is not as specified, replace the heated oxygen sensor.

Scheme 791

1. INSTALL HEATED OXYGEN SENSOR Using SST, install the heated oxygen sensor onto the front exhaust pipe. TEXT IN ILLUSTRATION *1 Fulcrum Length *2 30 mm SST: 09224-00010 without SST Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) with SST Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) NOTE: This torque value can be obtained by using a torque wrench with a fulcrum length of 300 mm (11.81 in.) and SST with a length of 30 mm (1.18 in.). Refer to «PRECAUTION»(ref-553290-S20522462032013051700000) . This torque value is effective when SST is parallel to the torque wrench. Install the wire harness clamp bracket and connect the wire harness clamp. Install the wire harness clamp bracket with the bolt. Torque: 12 N*m (127 kgf*cm, 9 ft.*lbf) Install the wire harness bracket. Connect the heated oxygen sensor connector.
2. INSPECT FOR EXHAUST GAS LEAK
3. INSTALL NO. 3 ENGINE UNDER COVER Install the No. 3 engine under cover with the 4 clips.

Scheme 792

Scheme 793

Scheme 794

1. REMOVE NO. 1 RELAY BLOCK COVER
2. REMOVE NO. 2 INTEGRATION RELAY Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws and disconnect the No. 2 integration relay. Disconnect the 3 connectors and remove the No. 2 integration relay.

Scheme 795

Scheme 796

1. INSPECT NO. 2 INTEGRATION RELAY TEXT IN ILLUSTRATION *1 No. 2 Integration Relay IG2 RELAY: Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *1 No. 2 Integration Relay Standard Resistance Tester Connection Condition Specified Condition No. 2 integration relay (1C-1) - No. 2 integration relay (1A-4) Auxiliary battery voltage is not applied between terminals 1A-2 and 1A-3 10 kohms or higher No. 2 integration relay (1C-1) - No. 2 integration relay (1A-4) Auxiliary battery voltage is applied between terminals 1A-2 and 1A-3 Below 1 ohms If the resistance is not as specified, replace the No. 2 integration relay. EFI MAIN RELAY: Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *1 No. 2 Integration Relay Standard Resistance Tester Connection Condition Specified Condition No. 2 integration relay (1C-1) - No. 2 integration relay (1B-4) Auxiliary battery voltage is not applied between terminals 1B-2 and 1B-3 10 kohms or higher No. 2 integration relay (1C-1) - No. 2 integration relay (1B-4) Auxiliary battery voltage is applied between terminals 1B-2 and 1B-3 Below 1 ohms If the resistance is not as specified, replace the No. 2 integration relay. C/OPN RELAY: Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *1 No. 2 Integration Relay Standard Resistance Tester Connection Condition Specified Condition No. 2 integration relay (1B-5) - No. 2 integration relay (1B-8) Auxiliary battery voltage is not applied between terminals 1B-6 and 1B-7 10 kohms or higher No. 2 integration relay (1B-5) - No. 2 integration relay (1B-8) Auxiliary battery voltage is applied between terminals 1B-6 and 1B-7 Below 1 ohms If the resistance is not as specified, replace the No. 2 integration relay. BATT FAN RELAY: Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *1 No. 2 integration Relay Standard Resistance Tester Connection Condition Specified Condition No. 2 integration relay (1C-1) - No. 2 integration relay (1A-8) Auxiliary battery voltage is not applied between terminals 1A-6 and 1A-7 10 kohms or higher No. 2 integration relay (1C-1) - No. 2 integration relay (1A-8) Auxiliary battery voltage is applied between terminals 1A-6 and 1A-7 Below 1 ohms If the resistance is not as specified, replace the No. 2 integration relay.

Scheme 797

1. INSTALL NO. 2 INTEGRATION RELAY Connect the 3 connectors. Attach the integration relay to the engine room relay block.
2. REMOVE NO. 1 RELAY BLOCK COVER