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Engine Mechanical [service Specifications] Toyota Prius V I

Mechanical

SERVICE DATA

Ignition timing	With Terminals TC and CG of DLC3 connected		8 to 12°BTDC at idle
Ignition timing	With Terminals TC and CG of DLC3 disconnected		0 to 16°BTDC at idle
Idle speed			950 to 1050 RPM
Compression	Compression pressure		813 kPa (8.3 kgf/cm 2 , 118 psi)
	Minimum pressure		617 kPa (6.3 kgf/cm 2 , 89.5 psi)
	Difference between each cylinder		100 kPa (1.0 kgf/cm 2 , 14.5 psi)
Oil pump drive gear	Minimum gear diameter (with chain)		48.2 mm (1.90 in.)
Oil pump drive shaft gear	Minimum gear diameter (with chain)		48.2 mm (1.90 in.)
Crankshaft timing gear	Minimum gear diameter (with chain)		51.1 mm (2.01 in.)
Chain tensioner slipper	Maximum wear		1.0 mm (0.0394 in.)
No. 1 chain vibration damper	Maximum wear		1.0 mm (0.0394 in.)
No. 2 chain vibration damper	Maximum wear		1.0 mm (0.0394 in.)
Chain tensioner plate	Maximum wear		1.0 mm (0.0394 in.)
Cylinder head set bolt	Standard bolt length		146.8 to 148.2 mm (5.78 to 5.83 in.)
Cylinder head set bolt	Maximum bolt length		149.2 mm (5.87 in.)
Cylinder head set bolt	Standard outside diameter		9.77 to 9.96 mm (0.385 to 0.392 in.)
Cylinder head set bolt	Minimum outside diameter		9.4 mm (0.3701 in.)
Ring pin (Cylinder head)	Protrusion		6.5 to 7.5 mm (0.256 to 0.295 in.)
Ring pin (Crankcase)	Protrusion height		3.0 mm (0.118 in.)
Straight pin (Camshaft housing)	Protrusion height		6.5 to 7.5 mm (0.256 to 0.295 in.)
No. 1 camshaft bearing	Dimension A-B		0.7 mm (0.0276 in.) or less
No. 2 camshaft bearing	Dimension A		1.05 to 1.75 mm (0.0413 to 0.0689 in.)
Chain sub-assembly	Maximum chain elongation		115.2 mm (4.54 in.)
No. 2 Chain sub-assembly	Maximum chain elongation		102.1 mm (4.02 in.)
Camshaft timing gear assembly	Minimum gear diameter (with chain)		96.8 mm (3.81 in.)
Camshaft timing sprocket	Minimum gear diameter (with chain)		96.8 mm (3.81 in.)
No. 1 camshaft
Maximum circle runout			0.04 mm (0.00157 in.)
Standard cam lobe height			41.779 to 41.879 mm (1.6448 to 1.6488 in.)
Minimum cam lobe height			41.629 mm (1.6389 in.)
No. 1 journal diameter			34.449 to 34.465 mm (1.3563 to 1.3569 in.)
Other journal diameter			22.949 to 22.965 mm (0.90350 to 0.90413 in.)
Standard thrust clearance	Intake		0.06 to 0.155 mm (0.00236 to 0.00610 in.)
Maximum thrust clearance	Intake		0.17 mm (0.00669 in.)
Standard oil clearance	Camshaft No. 1 journal		0.030 to 0.063 mm (0.00118 to 0.00248 in.)
Standard oil clearance	Camshaft Other journals		0.035 to 0.072 mm (0.00138 to 0.00283 in.)
Maximum oil clearance camshaft No. 1 journal			0.085 mm (0.00335 in.)
Maximum oil clearance camshaft other journals			0.09 mm (0.00354 in.)
No. 2 Camshaft
Maximum circle runout			0.04 mm (0.00157 in.)
Standard cam lobe height			43.346 to 43.446 mm (1.7065 to 1.7105 in.)
Minimum cam lobe height			43.196 mm (1.7006 in.)
No. 1 journal diameter			34.449 to 34.465 mm (1.3563 to 1.3569 in.)
Other journal diameter			22.949 to 22.965 mm (0.90350 to 0.90413 in.)
Standard thrust clearance	Exhaust		0.06 to 0.155 mm (0.00236 to 0.00610 in.)
Maximum thrust clearance	Exhaust		0.17 mm (0.00669 in.)
Standard oil clearance	Camshaft No. 1 journal		0.030 to 0.063 mm (0.00118 to 0.00248 in.)
Standard oil clearance	Camshaft Other journals		0.035 to 0.072 mm (0.00138 to 0.00283 in.)
Maximum oil clearance camshaft No. 1 journal			0.085 mm (0.00335 in.)
Maximum oil clearance camshaft other journals			0.09 mm (0.00354 in.)
Exhaust manifold	Maximum warpage		0.7 mm (0.0276 in.)
Cylinder head
Maximum warpage	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.)
Compression spring	Free length		53.36 mm (2.10 in.)
Compression spring	Maximum deviation		1.0 mm (0.0394 in.)
Intake valve	Standard overall length		109.34 mm (4.30 in.)
	Minimum overall length		108.84 mm (4.29 in.)
	Valve stem diameter		5.470 to 5.485 mm (0.215 to 0.216 in.)
	Standard margin thickness		1.0 mm (0.0394 in.)
	Minimum margin thickness		0.5 mm (0.0197 in.)
	Valve seat width		1.0 and 1.4 mm (0.0394 and 0.0551 in.)
Exhaust valve	Standard overall length		108.25 mm (4.26 in.)
	Minimum overall length		107.75 mm (4.24 in.)
	Valve stem diameter		5.465 to 5.480 mm (0.215 to 0.216 in.)
	Standard margin thickness		1.0 mm (0.0394 in.)
	Minimum margin thickness		0.5 mm (0.0197 in.)
	Valve seat width		1.0 and 1.4 mm (0.0394 and 0.551 in)
Intake valve guide bush	Bush inside diameter		5.510 to 5.530 mm (0.217 to 0.218 in.)
	Standard bush oil clearance		0.025 to 0.060 mm (0.00984 to 0.00236 in.)
	Maximum bush oil clearance		0.080 mm (0.00315 in.)
Bush bore diameter	Standard		10.285 to 10.306 mm (0.405 to 0.406 in.)
	Use STD		10.333 to 10.344 mm (0.4068 to 0.4072 in.)
	Use O/S 0.05		10.383 to 10.394 mm (0.4088 to 0.4092 in.)
Protrusion height			9.9 to 10.3 mm (0.390 to 0.406 in.)
Standard oil clearance			0.025 to 0.060 mm (0.000984 to 0.00236 in.)
Exhaust valve guide bush	Bush inside diameter		5.510 to 5.530 mm (0.217 to 0.218 in.)
	Standard oil clearance		0.030 to 0.065 mm (0.00118 to 0.00256 in.)
	Maximum oil clearance		0.085 mm (0.00335 in.)
Bush bore diameter	Standard		10.285 to 10.306 mm (0.405 to 0.406 in.)
	Use STD		10.333 to 10.344 mm (0.4068 to 0.4072 in.)
	Use O/S 0.05		10.383 to 10.394 mm (0.4088 to 0.4092 in.)
Protrusion height			11.15 to 11.55 mm (0.439 to 0.455 in.)
Standard oil clearance			0.030 to 0.065 mm (0.00118 to 0.00256 in.)
Protrusion height (ring pin)			6.5 to 7.5 mm (0.256 to 0.295 in.)
Valve seat width			1.0 to 1.4 mm (0.0394 to 0.0551 in.)
Spark Plug Tube	Standard Protrusion height		122 mm (4.80 in.)
Connecting rod
Standard thrust clearance			0.160 to 0.342 mm (0.00630 to 0.0135 in.)
Maximum thrust clearance			0.342 mm (0.0132 in.)
Standard oil clearance			0.014 to 0.038 mm (0.000551 to 0.00150 in.)
Maximum oil clearance			0.070 mm (0.00276 in.)
Connecting rod bearing thickness	Mark 1		1.489 to 1.493 mm (0.05862 to 0.05878 in.)
	Mark 2		1.494 to 1.497 mm (0.05882 to 0.05894 in.)
	Mark 3		1.498 to 1.501 mm (0.05898 to 0.05909 in.)
Connecting rod small end bore diameter			20.012 to 20.021 mm (0.78787 to 0.78823 in.)
Connecting rod small end bore diameter (Reference)	Mark A		20.012 to 20.015 mm (0.78787 to 0.78799 in.)
	Mark B		20.016 to 20.018 mm (0.78803 to 0.78811 in.)
	Mark C		20.019 to 20.021 mm (0.78815 to 0.78823 in.)
Connecting rod large end bore diameter (Resistance)	Mark 1		47.000 to 47.008 mm (1.85039 to 1.85071 in.)
	Mark 2		47.009 to 47.016 mm (1.85074 to 1.85102 in.)
	Mark 3		47.017 to 47.024 mm (1.85106 to 1.85133 in.)
Crankshaft pin diameter			43.992 to 44.000 mm (1.7320 to 1.7323 in.)
Standard oil clearance			0.005 to 0.011 mm (0.000197 to 0.000433 in.)
Maximum rod out-of alignment per 100 mm (3.94 in.)			0.05 mm (0.00197 in.)
Maximum rod twist per 100 mm (3.94 in.)			0.15 mm (0.00591 in.)
Cylinder block	Maximum warpage		0.05 mm (0.00197 in.)
	Standard cylinder bore diameter		80.500 to 80.513 mm (3.169 to 3.170 in.)
	Maximum cylinder bore diameter		80.63 mm (3.174 in.)
	Protrusion height (ring pin)		7.5 to 8.5 mm (0.295 to 0.335 in.)
	Protrusion height (straight pin)	Pin A	18.5 to 19.5 mm (0.728 to 0.768 in.)
		Pin B	5.0 to 7.0 mm (0.197 to 0.276 in.)
		Pin C	11 to 13 mm (0.433 to 0.512 in.)
		Pin D	8.0 to 10.0 mm (0.315 to 0.394 in.)
		Pin E	5.0 to 6.0 mm (0.197 to 0.236 in.)
No. 1 ventilation case	Seal packing		2.0 to 3.0 mm (0.0787 to 0.118in.)
Piston
Standard piston diameter			80.461 to 80.471 mm (3.1677 to 3.1681 in.)
Standard piston oil clearance			0.009 to 0.042 mm (0.000354 to 0.00165 in.)
Maximum piston oil clearance			0.08 mm (0.00315 in.)
Piston pin bore diameter			20.006 to 20.015 mm (0.78764 to 0.78799 in.)
Piston pin bore diameter (Reference)	Mark A		20.006 to 20.009 mm (0.78764 to 0.78775 in.)
	Mark B		20.010 to 20.012 mm (0.78779 to 0.78787 in.)
	Mark C		20.013 to 20.015 mm (0.78791 to 0.78799 in.)
Piston ring
Ring groove clearance	No. 1 Ring		0.02 to 0.07 mm (0.000787 to 0.00276 in.)
	No. 2 Ring		0.02 to 0.055 mm (0.000787 to 0.00217 in.)
	Oil Ring		0.02 to 0.06 mm (0.000787 to 0.00236 in.)
Standard end gap	No. 1 Ring		0.20 to 0.30 mm (0.00787 to 0.0118 in.)
	No. 2 Ring		0.30 to 0.45 mm (0.0118 to 0.0177 in.)
	Oil Ring		0.10 to 0.35 mm (0.00394 to 0.0138 in.)
Maximum end gap	No. 1 Ring		0.50 mm (0.0197 in.)
	No. 2 Ring		0.70 mm (0.0276 in.)
	Oil Ring		0.70 mm (0.0276 in.)
Piston pin
Piston pin diameter			20.004 to 20.013 mm (0.78756 to 0.78791 in.)
Piston pin diameter (Resistance)	Mark A		20.004 to 20.007 mm (0.78756 to 0.78768 in.)
	Mark B		20.008 to 20.010 mm (0.78771 to 0.78779 in.)
	Mark C		20.011 to 20.013 mm (0.78783 to 0.78791 in.)
Standard oil clearance			0.001 to 0.005 mm (-0.0000394 to 0.000197 in.)
Maximum oil clearance			0.010 mm (0.000394 in.)
Connecting rod bolt	Standard diameter		6.6 to 6.7 mm (0.260 to 0.264 in.)
Connecting rod bolt	Minimum diameter		6.4 mm (0.252 in.)
Crankshaft
Standard thrust clearance			0.04 to 0.14 mm (0.00157 to 0.00551 in.)
Maximum thrust clearance			0.18 mm (0.00709 in.)
Thrust washer thickness			2.43 to 2.48 mm (0.0957 to 0.0976 in.)
Cylinder block journal bore diameter (Reference)	Mark 0		52.000 to 52.002 mm (2.04724 to 2.04732 in.)
	Mark 1		52.003 to 52.004 mm (2.04736 to 2.04740 in.)
	Mark 2		52.005 to 52.006 mm (2.04744 to 2.04752 in.)
	Mark 3		52.007 to 52.009 mm (2.04752 to 2.04759 in.)
	Mark 4		52.010 to 52.011 mm (2.04763 to 2.04767 in.)
	Mark 5		52.012 to 52.013 mm (2.04771 to 2.04775 in.)
	Mark 6		52.014 to 52.016 mm (2.04779 to 2.04787 in.)
Main journal diameter			47.988 to 48.000 mm (1.8893 to 1.8898 in.)
Maximum taper and distortion			0.004 mm (0.000157 in.)
Main journal diameter (Reference)	Mark 0		47.999 to 48.000 mm (1.88972 to 1.88976 in.)
	Mark 1		47.997 to 47.998 mm (1.88964 to 1.88968 in.)
	Mark 2		47.995 to 47.996 mm (1.88956 to 1.88960 in.)
	Mark 3		47.993 to 47.994 mm (1.88948 to 1.88952 in.)
	Mark 4		47.991 to 47.992 mm (1.88941 to 1.88945 in.)
	Mark 5		47.988 to 47.990 mm (1.88929 to 1.88937 in.)
Crankshaft journal diameter (Reference)	Mark 0		47.999 to 48.000 mm (1.88972 to 1.88976 in.)
	Mark 1		47.997 to 47.998 mm (1.88964 to 1.88968 in.)
	Mark 2		47.995 to 47.996 mm (1.88956 to 1.88961 in.)
	Mark 3		47.993 to 47.994 mm (1.88948 to 1.88952 in.)
	Mark 4		47.991 to 47.992 mm (1.88941 to 1.88945 in.)
	Mark 5		47.988 to 47.990 mm (1.88929 to 1.88937 in.)
Standard main bearing center wall thickness (Reference)	Mark 1		1.994 to 1.997 mm (0.07850 to 0.07862 in.)
	Mark 2		1.998 to 2.000 mm (0.07866 to 0.07874 in.)
	Mark 3		2.001 to 2.003 mm (0.07878 to 0.07886 in.)
	Mark 4		2.004 to 2.006 mm (0.07890 to 0.07898 in.)
Maximum circle runout			0.03 mm (0.00118 in.)
Standard oil clearance			0.016 to 0.039 mm (0.000630 to 0.00154 in.)
Maximum oil clearance			0.050 mm (0.00197 in.)
Crank pin diameter			43.992 to 44.000 mm (1.7320 to 1.7323 in.)
Maximum taper and distortion			0.004 mm (0.000157 in.)
Crankshaft bearing cap set bolt	Standard diameter		84.3 to 85.7 mm (3.32 to 3.37 in.)
Crankshaft bearing cap set bolt	Minimum diameter		86.7 mm (3.41 in.)
Crankshaft bearing	Dimension A		0.5 to 1.0 mm (0.0197 to 0.0394 in.)
Crankshaft bearing	Dimension A-B		0.7 mm (0.0276 in.) or less

TORQUE SPECIFICATIONS

Part Tightened		N*m	Kgf*cm	Ft.*lbf
Engine mounting bracket RH x Engine mounting insulator RH	Nut A	95	969	70
	Nut B	52	530	38
	Bolt	95	969	70
Engine mounting insulator LH x Engine mounting bracket LH		56	571	41
Front engine mounting bracket x Front engine mounting insulator		145	1479	107
Rear engine mounting bracket x Rear engine mounting insulator		95	969	70
Radiator pipe x Hybrid vehicle transaxle assembly		19	194	14
Engine hanger x Cylinder head		43	438	32
Engine mounting insulator RH x body		95	969	70
Cooler bracket x body		9.8	100	87 in.*lbf
Engine mounting insulator LH x body		95	969	70
Front engine mounting insulator x Front crossmember		95	969	70
Earth wire x Engine		8.4	85	74 in.*lbf
Inverter tray bracket x Body		18	184	13
Inverter reserve tank assembly x Inverter tray bracket		10	102	7
Knock sensor x Cylinder block		20	204	15
Engine coolant temperature sensor x Cylinder head		20	204	15
Fuel vapor feed pipe x Cylinder head cover		43	438	32
Engine oil level dipstick guide x Cylinder block		21	214	16
Engine oil level dipstick guide x Intake manifold		28	286	21
Flywheel sub-assembly x Crankshaft		49	500	36
Flywheel sub-assembly x Crankshaft		Turn 90°	Turn 90°	Turn 90°
Transmission input damper assembly x Flywheel sub-assembly		30	306	22
Front crossmember x Body		96	979	71
Air cleaner case x Body		7.0	71	62 in.*lbf
Inlet air cleaner assembly x Engine mounting insulator RH		7.0	71	62 in.*lbf
Inlet air cleaner assembly x Intake manifold		7.0	71	62 in.*lbf
Inlet air cleaner assembly x Body		7.0	71	62 in.*lbf
Stiffening crankcase assembly x Cylinder block		21	214	15
No. 1 oil nozzle sub-assembly x Cylinder block		10	102	7
No. 1 ventilation case x Cylinder block		10	102	7
No. 1 taper screw plug x Stiffening crankcase assembly	Plug A	25	255	18
No. 1 taper screw plug x Stiffening crankcase assembly	Plug B	43	439	32
Cylinder head sub-assembly x Cylinder block	1st	49	500	36
	2nd	Turn 90°	Turn 90°	Turn 90°
	3nd	Turn 45°	Turn 45°	Turn 45°
Camshaft timing gear assembly x Camshaft		54	551	40
Camshaft timing sprocket x Camshaft		54	551	40
Camshaft bearing cap x Cylinder head		27	275	20
Camshaft bearing cap x Camshaft housing		16	163	12
Camshaft housing x Cylinder head		27	275	20
No. 2 chain vibration damper x Cylinder head		10	102	7
No. 1 chain vibration damper x Cylinder block		21	214	15
Oil pan drain plug x Oil pan		37	377	27
Water inlet x Timing chain cover		10	102	7
Camshaft timing oil control valve x Cylinder head cover		10	102	7
Crankshaft position sensor x Timing chain cover		10	102	7 ft.*lbf
Crankshaft pulley x Crankshaft		190	1937	140
Timing chain cover x Cylinder block, Cylinder head, Oil pan	Bolt A, E, F	26	260	19
	Bolt B, C	51	520	38
	Bolt D	10	102	7
No. 1 chain tensioner assembly x Timing chain cover		12	122	9
Camshaft position sensor x Cylinder head cover		10	102	7
Engine cover joint x Cylinder head cover		10	102	7
Cylinder head cover sub-assembly x Cylinder head		10	102	7
Wiring harness clamp bracket x Cylinder head cover		10	102	7
No. 2 straight screw plug x Cylinder head		44	449	32
Stud bolt x Cylinder head	Bolt A	9.5	97	84 in.*lbf
Stud bolt x Cylinder head	Bolt B	9.5	97	84 in.*lbf
Stud bolt x Crankcase		5.0	51	44 in.*lbf
Crankshaft bearing cap x Cylinder block	1st	40	408	30
Crankshaft bearing cap x Cylinder block	2nd	Turn 90°	Turn 90°	Turn 90°
Connecting rod cap x Connecting rod	1st	20	204	15
Connecting rod cap x Connecting rod	2nd	Turn 90°	Turn 90°	Turn 90°