TOYOTA PRIUS 2001 Service Repair Manual

BR±6
± BRAKEBRAKE FLUID
1521 Author: Date:
2001 PRIUS (RM778U)
HINT:
Do not keep the solenoid activated for 2 seconds, or more. Al-
low an interval of 20 seconds, or more if activating it continuous-
ly.
(r) Turn the SRRR solenoid OFF with the TOYOTA hand±
held tester, and release the brake pedal.
(s) Check that the pump motor stops after 20 seconds.
(t) Repeat step (q) to (s) 3 times.
(u) Turn the ignition switch OFF, and disconnect the TOYOTA
hand±held tester from DLC3.
(v) Clear the DTC (See page DI±353).
HINT:

Diagnosis codes are erased with the shift lever in P range.

After erasing, turn the ignition switch OFF to protect ECU.
4. CHECK FLUID LEVEL IN RESERVOIR
(a) With the ignition switch OFF, depress the brake pedal
more than 40 times.
(b) Remove the reservoir cap. Add brake fluid up to the
ºMAXº line.
Fluid: SAE J1703 or FMVSS NO. 116 DOT3

BR1JA±01
F12629
Front Door Scuff Plate Cowl Side TrimHood Lock Release
Lever Lower Column CoverRadio Tuner Opening CoverCluster Finish Panel
Assembly Hazard Warning Switch
Lower Center Cluster
Finish PanelGlove Compartment
Door Finish PanelInstrument PanelNo. 3 Register No. 2 Side Defroster
Nozzle
Front Pillar GarnishPassenger Air Bag
Assembly Cluster Finish Panel
Combination Meter
Lower Finish PanelSteering Wheel Pad Steering Wheel
Spiral CableUpper Column Cover
Front Door Scuff PlateCowl Side Trim No. 1 RegisterNo. 1 Side Defroster
NozzleFront Pillar Garnish
: Specified torqueN´m (kgf´cm, ft´lbf)
50 (510, 37)
BR±10
± BRAKEPARKING BRAKE PEDAL
2001 PRIUS (RM778U)
COMPONENTS

F12632
Parking Brake Wire
Lock NutAdjusting Nut
Return Spring
Pedal AssemblyPedal Bracket
Pedal PadCushion Plate
Parking Brake switch
5.4 (55, 48 in.´lbf)
Lithium soap base glycol grease: Specified torque
N´m (kgf´cm, ft´lbf)

Non±reusable part
Bushing

Bushing Clip
14 (143, 10)
Parking Brake Pedal Assembly
Nut
32 (327, 24)
13 (130, 9)
± BRAKEPARKING BRAKE PEDAL
BR±11
2001 PRIUS (RM778U)

BR1JF±01
F12415
Wiper Arm
Cowl Top Ven-
tilator Louver
LH
Hood to Cowl Top Seal
Wiper Motor & Link Assembly
Outer Front Cowl Top Panel
Converter and Inverter
Assembly
Front Door Scuff PlateLower Finish Panel Cowl Top Ventilator Louver RH
Finish Panel Engine Room
R/B No. 2

Gasket Clip
Cowl Side Trim
13 (130, 9)
Clevis PinWave Washer
Clip
Return Spring
Circuit Breaker
SensorMG 2
MG 1
20 (204, 15)
8.0 (82, 71 in.´lbf)
Clip
Lithium soap base glycol grease: Specified torque
N´m (kgf´cm, ft´lbf)

Non±reusable part
Reservoir Hose
Master Cylinder Reservoir Hose
8.0 (82, 71 in.´lbf)
8.0 (82, 71 in.´lbf)
Inverter Terminal
Cover

Gasket
Hood Lock Release
Lever
Connector Cover
Wiper Motor Cover
21 (214, 15)
26 (270, 20)
7.4 (75, 64 in.´lbf)
5.4 (55, 48 in.´lbf)
15 (155, 11)
21 (214, 15)
BR±16
± BRAKEBRAKE MASTER CYLINDER
1531 Author: Date:
2001 PRIUS (RM778U)
BRAKE MASTER CYLINDER
COMPONENTS

F12630
Clevis Clevis Lock Nut
Cylinder Boot
No. 2 Piston
Lithium soap base glycol grease: Specified torque
N´m (kgf´cm, ft´lbf)
Master Cylinder Body

Non±reusable part
No. 1 Piston

Plug
Snap Ring
26 (265, 19)
± BRAKEBRAKE MASTER CYLINDER
BR±17
1532 Author: Date:
2001 PRIUS (RM778U)

F12057
BR1J3±01
F12058
BR±24
± BRAKEFRONT BRAKE PAD
2001 PRIUS (RM778U)
REPLACEMENT
1. REMOVE FRONT WHEEL
2. INSPECT PAD LINING THICKNESS
Check the pad thickness through the caliper inspection hole
and replace the pads if they are not within the specification.
Minimum thickness: 1.0mm (0.039 in.)
3. LIFT UP CALIPER
(a) Hold the sliding pin and remove the bottom side installa-
tion bolt.
HINT:
Do not disconnect the flexible hose from the brake caliper.
(b) Lift up the caliper and suspend it securely.
4. REMOVE 2 PADS WITH 4 ANTI±SQUEAL SHIMS
5. REMOVE 2 PAD SUPPORT PLATES
NOTICE:
The support plates can be used again provided that they
have sufficient rebound, no deformation, cracks or wear,
and have had all rust, dirt and foreign particles cleaned off.
6. CHECK DISC THICKNESS AND RUNOUT
(See page BR±29 )
7. INSTALL PAD SUPPORT PLATES
Install the 2 pad support plates.
NOTICE:
Do not assemble the upper and lower pad support plates
in reverse.
8. INSTALL NEW PADS
NOTICE:
When replacing worn pads, the anti±squeal shims must be
replaced together with the pads.
(a) Apply disc brake grease to both side of the inner anti±
squeal shim (See page BR±23).
(b) Install the 2 anti± squeal shims on each pad.
(c) Install the inner pad with the pad wear indicator plate fac-
ing upward.
(d) Install the outer pad.
NOTICE:
There should be no oil or grease adhering to the friction
surfaces of the pads or the disc.

F12060
± BRAKEFRONT BRAKE PAD
BR±25
2001 PRIUS (RM778U)
9. INSTALL CALIPER
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in the piston with a hammer handle or similar imple-
ment.
HINT:

Tape the hammer handle before use.

If the piston is difficult to push in, loosen the bleeder plug
and push in the piston while letting some brake fluid es-
cape.
(c) Install the caliper.
(d) Hold the sliding pin and torque the installation bolts.
Torque: 34 N´m (350 kgf´cm, 25 ft´lbf)
10. INSTALL FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
11. DEPRESS BRAKE PEDAL SEVERAL TIMES
12. CHECK THAT FLUID LEVEL IS AT MAX LINE

BR14B±02
F12395
F07782
F12387
SST
F12388SST
± BRAKEREAR DRUM BRAKE
BR±33
2001 PRIUS (RM778U)
REMOVAL
1. INSPECT SHOE LINING THICKNESS
Remove the inspection hole plug, and check the shoe lining
thickness through the hole.
If less than minimum, replace the shoes.
Minimum thickness: 1.0 mm (0.039 in.)
2. REMOVE REAR WHEEL
3. REMOVE BRAKE DRUM
(a) Release the parking brake pedal, and remove the brake
drum.
HINT:
If the brake drum cannot be removed easily, do the following
steps.
(b) Remove the plug and insert a screwdriver through the
hole in the backing plate.
(c) Using another screwdriver, reduce the brake shoe adjust-
er by turning the adjusting wheel.
4. REMOVE FRONT SHOE
(a) Using SST, disconnect the return spring from the rear
shoe.
SST 09703±30010
(b) Using needle±nose pliers, remove the anchor spring.
(c) Using SST, remove the cap, shoe hold±down spring and
pin from the front shoe.
SST 09718±00010
(d) Remove the adjuster and return spring together with the
front shoe.
(e) Using needle±nose pliers, remove the adjusting lever
spring.
(f) Remove the automatic adjusting lever from the front
shoe.
5. REMOVE REAR SHOE
(a) Using SST, remove the cap, shoe hole±down spring and
pin.
SST 09718±00010

F09780
F12390
SST
BR±34
± BRAKEREAR DRUM BRAKE
2001 PRIUS (RM778U)
(b) Using needle±nose pliers, disconnect the parking brake
cable from the parking brake lever, and remove the rear
shoe.
6. REMOVE PARKING BRAKE LEVER
(a) Remove the C±washer.
(b) Remove the parking brake lever from the rear shoe.
7. REMOVE WHEEL CYLINDER
(a) Using SST, disconnect the brake line. Use container to
catch the brake fluid.
SST 09751±36011
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
(b) Remove the bolt and the wheel cylinder.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
8. DISASSEMBLE WHEEL CYLINDER
(a) Remove the 2 boots from the wheel cylinder.
(b) Remove the 2 pistons from the wheel cylinder.
(c) Remove the spring from the wheel cylinder.
(d) Remove the 2 piston cups from each piston.

BR0K8±14
F12416
Reservoir
Brake Actuator HoseBrake Reservoir
Hose No. 2
Reservoir BracketRight Front Brake Line
ClipWiper Arm
Cowl Top Ventilator Louver RH
Hood to Cowl Top Seal
Outer Front Cowl Top PanelCowl Top Ventilator Louver LH
Brake Reservoir
Hose No. 1
Clamp

Non±reusable part: Specified torque
N´m (kgf´cm, ft´lbf)Clip
Clamp Bracket Engine Room R/B No. 2
15 (155, 11)
Lipuid and Suction Tube
Hydraulic Brake
Booster Assembly
19 (194, 14)
19 (194, 14)
Wiper Motor Cover
Sub±bracket
19 (194, 14)
19 (194, 14)
5.4 (55, 48 in.´lbf)
26 (270, 20)
7.4 (75, 64 in.´lbf)
7.5 (77, 66 in.´lbf)
Wiper Motor &
Link Assembly
18 (184, 13)
BR±42
± BRAKEHYDRAULIC BRAKE BOOSTER
2001 PRIUS (RM778U)
COMPONENTS