OEM 2001 Toyota Prius Timing Chain

2001 Toyota Prius Parts Questions & Experts Answers

• Q: How to remove the timing chain on 2001 Toyota Prius?

  A: The procedure for timing chain removal starts by removing the battery negative terminal and HV battery service plug followed by taking out the outer front cowl top panel assembly and right-hand engine under cover. The engine coolant drain and air cleaner assembly removal process begins with disconnecting the MAP meter connector and the EVAP hose while loosening its two hose clamps and removing three bolts from the assembly. Begin by detaching the brake reservoir tank through the removal of two bolts after disconnecting its brake fluid level sensor connector: finally suspend the tank before erasing its three bracket bolts. Disconnect first the ignition connectors and injector connectors and afterwards the camshaft position sensor connector as well as water temperature connector and camshaft timing oil control valve connector and two VSV connectors. A jack underneath the engine and wooden block between engine and jack enables removal of the air inlet alongside the engine coolant reservoir tank and VSV from the engine mounting insulator, drive belt, and right-hand engine mounting insulator through five bolts and two nuts. The engine wire needs disconnection from the cylinder head cover through three bolt removal. After engine wire removal, the cylinder head cover can be detached by unpicking ignition coils and two PCV hoses along with seven bolts, two seal washers and two nuts. To set the No.1 cylinder at TDC/compression position adjust the crankshaft pulley until its groove lines up with the timing mark "0" while both camshaft timing sprocket and valve timing controller assembly timing marks should be oriented vertically upward. The removal process of the crankshaft pulley requires Special Service Tools including 09213-70010, 09330-00021, in addition to potential assistance from 09950-50012 (09951-05010, 09952-05010, 09953-05020, 09954-05020). You must first remove the crankshaft position sensor and right-hand engine mounting bracket followed by the water pump and oil control valve and timing chain cover through bolting off all 13 bolts and a nut while removing the stud bolt with a torx wrench socket (E8). Gentle pry removal of the cover remains essential to avoid damage. The first step includes removing both O-rings present on the cylinder block and oil pan No.1 after proper extraction of the chain tensioner and its corresponding slipper and vibration damper. Examine the timing sprockets and chain to check that the maximum chain elongation reaches 123.2 mm (4.850 inch) and its sprocket diameters maintain at least 96.2 mm (3.787 inch) for camshaft and 50.5 mm (1.988 inch) for crankshaft. Examine both timing chain components: slipper and vibration damper where wear should be below 1.0 mm (0.039 inch). Insert the new crankshaft front oil seal through Special Service Tool: 09612-22011 until it reaches timing chain cover edge. First cut the oil seal lip then remove it with caution before inserting the new seal. The installation process starts with positioning the crankshaft within an ATDC range of 40 to 140 degrees before setting the intake and exhaust sprockets at 20 degrees ATDC and resetting the crankshaft at 20 degrees ATDC. Install the chain vibration damper using two bolts that should have a torque setting of 9.0 Nm while aligning the match marks of the timing chain and placing the chain tensioner slipper. The chain tensioner should be installed by applying force to the plunger before rotating the lock plate and inserting a 2.5 mm (0.098 inch) bar then using two bolts tightened to 9.0 Nm (92 kgf-cm, 80 inch lbs.). The timing chain cover receives a surface cleaning before receiving seal packing (Part No. 08826-00100 or equivalent) to be installed with the water pump and new O-rings by using 16 bolts and three nuts following specified torque requirements. Fasten the right-hand engine mounting bracket first before adding the crankshaft position sensor and oil control valve after which the crankshaft pulley gets installed while following torque parameter guidelines. The procedure ends by installing the cylinder head cover with packing and new wires before connecting the engine wire then installing the ignition coils followed by reassembly of other components such as the air cleaner assembly and brake reservoir tank and the outer front cowl top panel assembly. Before testing the vehicle do a test drive to check smooth functioning and identify any abnormal noises and recheck both engine coolant and HV transaxle coolant levels. The necessary testing requires engine coolant filling followed by negative battery terminal (-) and HV battery service plug connection.