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Valve Cover Gasket Replacement

Discussion in 'Generation 1 Prius Discussion' started by boywithoutafairy, Sep 20, 2019.

  1. boywithoutafairy

    boywithoutafairy Junior Member

    Joined:
    Sep 20, 2019
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    Location:
    Los Angeles
    Vehicle:
    2001 Prius
    Model:
    N/A
    Hello all!

    My 1st gen started stalling and after replacing the MAF sensor, cleaning the throttle body, and checking all other aspects related to engine stalls, I checked the spark plugs and (you guessed it) found some oil. I attempted to access the valve cover and successfully removed the cowl, loosened everything up, but for the life of me, I couldn't get this plastic cover protecting the wire harness for the ignition coils and fuel injectors off. It seems to fit snuggly on the right side of the valve cover with no clear way of removing/setting it aside. My YouTube mechanical experience is limited, so fearing to break such important components I decided to leave it for more experienced hands.

    I'd thought I'd pop by here and see if anyone has any advice for removing or setting it aside to access the valve cover. It would be a shame to fork over ~$200.00 for a job that I can do myself with a little patience. Plus, I would love the experience, knowledge, and satisfaction that comes with a job well done.

    Thanks!
     
    #1 boywithoutafairy, Sep 20, 2019
  2. mroberds

    mroberds Member

    Joined:
    Nov 6, 2010
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    Location:
    .
    Vehicle:
    2001 Prius
    Model:
    N/A
    Disclaimer: I've never tried to take this part off of my 2001. This is just going from the service manual. It's raining right now, so I haven't gone and looked under the hood of my car. :)

    The exploded diagram on page EM-27* of the 2001 manual shows an "engine wire" vaguely near the transmission end of the cylinder head. In the middle of the run, it's shown as having one multi-pin connector, and two wires with ring terminals on them, coming out of the harness. There are two plastic hoops around the harness with a plastic socket attached to the hoop, about evenly spaced in front and in back of the wires that come out. The plastic sockets plug onto metal L-brackets, which have nuts on the other end that fasten them to something.

    *probable Techninfo path: Engine and Hybrid System > Engine Mechanical > Cylinder Head > Components

    The relevant disassembly step seems to be on page EM-16 (probable Techinfo path: Engine and Hybrid System > Engine Mechanical > Timing Chain > Removal):

    13. DISCONNECT ENGINE WIRE FROM CYLINDER HEAD COVER
    Remove the 3 bolts and disconnect the engine wire from the cylinder head.

    One of the pictures in this procedure shows an overall view of the engine, with a connector near the pulley end, and the four injector connectors. On the transmission end, there's an inset view, with an arrow pointing at two connectors and two bolts for ring terminals. To look where the inset arrow is telling you to look, you'd need to put your head where the inverter currently is, and look at the transmission end of the valve cover. (You don't actually have to remove the inverter; I'm just describing the viewpoint.) That inset shows two wires with ring terminals on them, plus two multi-pin connectors.

    I'm guessing that two of the three bolts mentioned in the step are for the ring terminals. I'm not sure what the third bolt is, but I'd guess it might be for one of the L-brackets that goes to the engine wire.
     
    #2 mroberds, Sep 21, 2019
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