Engine Control System (Service Information) (Except Phv): Removal & Installation Toyota Prius III

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 97»(ref-393186-S28192021342011040700000)

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1. INSTALL THROTTLE BODY ASSEMBLY Install a new gasket onto the intake manifold. Install the throttle body assembly with the 2 bolts and 2 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the 2 water by-pass hoses and throttle body connector.
2. INSTALL AIR CLEANER HOSE ASSEMBLY Install the air cleaner hose assembly and lock the hose clamp. Connect the ventilation hose.
3. INSTALL AIR CLEANER CASE Install the air cleaner case with the 3 bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) Install the hose to the 3 hose clamps. Install the air cleaner filter element.
4. INSTALL INLET AIR CLEANER ASSEMBLY Install the inlet air cleaner assembly with the 3 bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) Connect the wire harness clamp to the inlet air cleaner assembly. Install the hose to the hose clamp.
5. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Install the air cleaner cap sub-assembly with the 2 clamps. Tighten the hose clamp. Connect the mass air flow meter connector.
6. ADD ENGINE COOLANT (for Engine) . Refer to «REPLACEMENT - Step 4»(ref-393175-S35674032612011040700000)
7. INSPECT FOR COOLANT LEAK (for Engine) . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-393190-S41700106582011040700000)
8. INSTALL NO. 2 CYLINDER HEAD COVER . Refer to «INSTALLATION - Step 97»(ref-393186-S28192021342011040700000)
9. INSTALL NO. 1 ENGINE UNDER COVER
10. PERFORM INITIALIZATION NOTE: Be sure to perform this procedure after reassembling the throttle body assembly, removing and reinstalling any throttle body component or replacing the ECM. Disconnect the cable from the negative (-) battery terminal. Wait at least 60 seconds and reconnect the cable. Connect the Techstream to the DLC3 and clear the DTCs. Refer to «DTC CHECK/CLEAR»(ref-393183-S13119469612011040700000) . Set the vehicle to the inspection mode. Refer to «INSPECTION MODE PROCEDURE»(ref-393046-S20890913792011040700000) . Start the engine without operating the accelerator pedal and check that the MIL is not illuminated and that the idle speed is within the specified range when the air conditioning is switched off after the engine is warmed up. Standard Condition Engine Idle Speed A/C switched off 950 to 1050 rpm NOTE: If the accelerator pedal is operated, perform the above steps again. Be sure to perform this step with all accessories off. Make sure that park (P) is selected. Perform a road test and confirm that there are no abnormalities.

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1. REMOVE REAR NO. 2 FLOOR BOARD (for Separate Type) . Refer to «REMOVAL - Step 1»(ref-393197-S13745830712011040700000)
2. REMOVE REAR DECK FLOOR BOX . Refer to «REMOVAL - Step 2»(ref-393197-S13745830712011040700000)
3. REMOVE REAR NO. 3 FLOOR BOARD . Refer to «REMOVAL - Step 3»(ref-393197-S13745830712011040700000)
4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION»(ref-393046-S17843422982011040700000) .
5. SEPARATE RADIATOR WITHOUT CAP RESERVE TANK ASSEMBLY Remove the 2 bolts and separate the radiator without cap reserve tank assembly.
6. REMOVE ECM Remove the No. 1 relay block cover. Disconnect the 3 wire harness connectors. Disengage the 2 claws, push up the engine room wire harness and separate it from the engine room relay block. Disengage the 2 claws and push up the side cover to remove it. Loosen the bolt and separate the No. 2 engine room wire. Disconnect the 2 ECM connectors. Disconnect the 2 wire harness clamps. Push the locks on the 2 levers, then raise the levers, and disconnect the 2 ECM connectors. NOTE: After disconnecting the connectors, make sure that dirt, water or other foreign matter does not contact the connecting parts of the connectors. Separate the 2 wire harness clamps. Remove the 2 bolts and ECM with 2 ECM brackets.

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1. INSTALL ECM Install the ECM with the 2 bolts. Torque: 13 N.m (133 kgf*cm, 10 ft.*lbf) Install the 2 wire harness clamps. Connect the 2 ECM connectors. Connect the 2 ECM connectors and lower the 2 levers. NOTE: When connecting the connectors, make sure that dirt, water or other foreign matter does not get caught between the connectors and other parts. Make sure that the 2 levers are securely locked. Install the 2 wire harness clamps. Install the No. 2 engine room wire with the bolt. Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) Slide the side cover down and engage the 2 claws to install it. Slide the engine room wire harness down and engage the 2 claws to install it. Connect the 3 wire harness connectors. Install the No. 1 relay block cover.
2. INSTALL RADIATOR WITHOUT CAP RESERVE TANK ASSEMBLY Install the radiator without cap reserve tank assembly with the 2 bolts. Torque: 18 N.m (184 kgf*cm, 13 ft.*lbf)
3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION»(ref-393046-S17843422982011040700000) .
4. INSTALL REAR NO. 3 FLOOR BOARD . Refer to «INSTALLATION - Step 58»(ref-393197-S31731625852011040700000)
5. INSTALL REAR DECK FLOOR BOX . Refer to «INSTALLATION - Step 59»(ref-393197-S31731625852011040700000)
6. INSTALL REAR NO. 2 FLOOR BOARD (for Separate Type) . Refer to «INSTALLATION - Step 60»(ref-393197-S31731625852011040700000)
7. PERFORM INITIALIZATION HINT: Initialization cannot be completed by only disconnecting and reconnecting the cable of the negative (-) battery terminal. Perform Initialization when replacing the ECM. See step 10 .

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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 97»(ref-393186-S28192021342011040700000)

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REMOVAL

HINT

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

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1. REMOVE NO. 2 CYLINDER HEAD COVER . Refer to «REMOVAL - Step 29»(ref-393186-S13883042542011040700000)
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.

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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 97»(ref-393186-S28192021342011040700000)

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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.

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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

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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

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1. REMOVE WINDSHIELD WIPER MOTOR AND LINK Remove the windshield wiper motor and link. Refer to «REMOVAL»(ref-393198-S35537952522011040700000) .
2. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to «REMOVAL - Step 8»(ref-393171-S28519972432011040700000)
3. REMOVE NO. 2 CYLINDER HEAD COVER . Refer to «REMOVAL - Step 29»(ref-393186-S13883042542011040700000)
4. 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.
5. 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 97»(ref-393186-S28192021342011040700000)
4. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to «INSTALLATION - Step 16»(ref-393171-S38878422782011040700000)
5. INSTALL WINDSHIELD WIPER MOTOR AND LINK Remove the windshield wiper motor and link. Refer to «INSTALLATION»(ref-393198-S25012450142011040700000) .

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1. REMOVE EGR WITH COOLER PIPE SUB-ASSEMBLY Remove the EGR with cooler pipe sub-assembly. Refer to «REMOVAL»(ref-393178-S11821325892011040700000) .
2. REMOVE RADIATOR WITHOUT CAP RESERVE TANK ASSEMBLY See step 5
3. REMOVE ENGINE COOLANT TEMPERATURE SENSOR Disconnect the engine coolant temperature sensor connector. Remove the engine coolant temperature sensor.

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1. INSPECT 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 the engine coolant temperature sensor through a new gasket. Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf) Connect the engine coolant temperature sensor connector.
2. INSTALL RADIATOR WITHOUT CAP RESERVE TANK ASSEMBLY See step 2
3. INSTALL EGR WITH COOLER PIPE SUB-ASSEMBLY Install the EGR with cooler pipe sub-assembly. Refer to «INSTALLATION»(ref-393178-S14522981002011040700000) .

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1. REMOVE INTAKE MANIFOLD Remove the intake manifold. Refer to «REMOVAL»(ref-393194-S19898183422011040700000) .
2. REMOVE KNOCK SENSOR Disconnect the knock sensor connector. Remove the bolt and remove the knock sensor.

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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.

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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-393194-S02839864822011040700000) .

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1. REMOVE WINDSHIELD WIPER MOTOR AND LINK Remove the windshield wiper motor and link. Refer to «REMOVAL»(ref-393198-S35537952522011040700000) .
2. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to «REMOVAL - Step 8»(ref-393171-S28519972432011040700000)
3. REMOVE NO. 2 CYLINDER HEAD COVER . Refer to «REMOVAL - Step 29»(ref-393186-S13883042542011040700000)
4. 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

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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) 1.8 to 3.4 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.

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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.). The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 300 mm (11.81 in.). Refer to «PRECAUTION»(ref-393046-S19712442022011040700000) . This 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 97»(ref-393186-S28192021342011040700000)
3. INSPECT FOR EXHAUST GAS LEAK
4. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to «INSTALLATION - Step 16»(ref-393171-S38878422782011040700000)
5. INSTALL WINDSHIELD WIPER MOTOR AND LINK Install the windshield wiper motor and link. Refer to «INSTALLATION»(ref-393198-S25012450142011040700000) .

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1. REMOVE NO. 2 ENGINE UNDER COVER Remove the 4 clips and No. 2 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

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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.

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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-393046-S19712442022011040700000) . 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. Pass the sensor connector through the floor panel and install the grommet. Connect the heated oxygen sensor connector.
2. INSPECT FOR EXHAUST GAS LEAK
3. INSTALL NO. 2 ENGINE UNDER COVER Install the No. 2 engine under cover with the 4 clips.

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

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

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