OEM 2002 Toyota Prius Timing Chain

2002 Toyota Prius Parts Questions & Experts Answers

• Q: How to service and repair the timing chain on 2002 Toyota Prius?

  A: Service and repair of the timing chain begins by disconnecting the battery negative (-) terminal along with the HV battery service plug then removing the outer front cowl top panel assembly and right-hand engine under cover and draining the engine coolant. Start by unconnecting both the MAF meter connector and the EVAP hose and loosening their clamps before removing all bolts to take out the air cleaner assembly. The brake reservoir tank needs detachment by removing the bolts and brake fluid level sensor connector before suspending it into the air. The mechanic should disconnect the ignition and injector and VSV and camshaft position sensor and water temperature connectors. After setting a wooden block between the jack and engine start by disconnecting the VSV from the engine mount along with the right-hand engine mount and the drive belt and engine coolant reservoir tank and air inlet. After disconnecting the engine wire from the cylinder head cover you can remove it by removing ignition coils along with PCV hoses and bolts, nuts and gasket. Place the No. 1 cylinder at TDC/compression by positioning the crankshaft pulley mark against "0" when the timing marks on both camshaft timing sprocket and valve timing controller assembly require precise alignment. The crankshaft pulley requires the use of Special Service Tools 09213-70011 and 09330-00021, Special Service Tool 09950-50013 should be used if necessary. Use a screwdriver to remove crankshaft position sensor along with the right-hand engine mounting bracket and water pump and oil control valve while timing chain cover and its O-rings should be removed after unscrewing their studs and bolts followed by gentle prying. Take out the chain tensioner and its slipper along with the vibration damper from the system. The inspecting team must thoroughly examine both timing chain components and sprockets to verify a maximum elongation below 123.2 mm (4.850 inch) and correct sprocket dimension maintenance. Examine the chain tensioner slipper along with the vibration damper for wear to verify they fall below 1.0 mm (0.039 inch) in measurement. Special Service Tool: 09612-22011 helps installation of a new oil seal after the old lip has been cut off and the oil seal has been pried out. Installation requires placing the crankshaft at ATDC 40 - 140 degrees then setting intake and exhaust sprocket alignment before applying the specified torque to the chain vibration damper. Set the match marks of the timing chain while installing the chain tensioner slipper. You should install the chain tensioner so the plunger functions without resistance before it secures its position. Fitting procedure requires contacting surface cleaning and the application of seal packing (Part No. 08826-00100 or equivalent) onto the timing chain cover. Install the timing chain cover together with the water pump along with correct tightening of its bolts and nuts according to specifications. Mount the right-hand engine bracket with Part No. 08826-00080 or equivalent seal packing then apply specified torque on the bolts. Use specified torque values for installing the crankshaft position sensor together with the oil control valve and crankshaft pulley. Use new packing to install the cylinder head cover by allowing correct assembly duration before connecting the engine wire. The installation process involves returning ignition coils, right-hand engine mounting insulator and VSV and drive belt and engine coolant reservoir tank along with air inlet while reconnecting all device connectors. The service process concludes with the following sequence: filling the system with engine coolant followed by engine under cover installation and battery plug and negative terminal reconnection and a road test for noise and operational checks then a second coolant check.