TOYOTA PRIUS 2001 Service Repair Manual

SA1ZW±01
F11576
SST
F11616
F11617
F11586
± SUSPENSION AND AXLEFRONT LOWER SUSPENSION ARM
SA±33
2001 PRIUS (RM778U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. REMOVE ENGINE UNDER COVER
3. REMOVE LOWER SUSPENSION ARM
(a) Disconnect the RH and LH tie rod ends.
(1) Remove the cotter pin and nut.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
(2) Using SST, disconnect the tie rod end from the
steering knuckle.
SST 09628±62011
(3) Employ the same manner described above to the
other side.
(b) Disconnect the RH and LH stabilizer bar links.
(1) Remove the nut and disconnect the stabilizer bar
link from the shock absorber.
Torque: 74 N´m (755 kgf´cm, 55 ft´lbf)
HINT:
If the ball joint turns together with the nut, use a hexagon (5 mm)
wrench to hold the stud.
(2) Employ the same manner described above to the
other side.
(c) Disconnect the RH and LH lower suspension arms from
the lower ball joints.
(1) Remove the bolt and 2 nuts, and disconnect the
lower suspension arm from the lower ball joint.
Torque: 142 N´m (1,450 kgf´cm, 105 ft´lbf)
(2) Employ the same manner described above to the
other side.
(d) Loosen the 2 lower suspension arm set bolts.
Torque: 137 N´m (1,397 kgf´cm, 101 ft´lbf)
HINT:
At the time of installation, after stabilizing the suspension,
torque the bolts.
(e) Disconnect the sliding yoke (See page SR±6).
(f) Support the suspension member with a transmission
jack.

F12936
F12933
SA±34
± SUSPENSION AND AXLEFRONT LOWER SUSPENSION ARM
2001 PRIUS (RM778U)
(g) Remove the bolt and nut, disconnect the torque rod from
the suspension member.
Torque: 100 N´m (1,150 kgf´cm, 83 ft´lbf)
(h) Remove the 4 bolts and disconnect the suspension mem-
ber from the body.
Torque:
Front side: 113 N´m (1,152 kgf´cm, 83 ft´lbf)
Rear side: 157 N´m (1,600 kgf´cm, 116 ft´lbf)
(i) Remove the 2 lower suspension arm set bolts and discon-
nect the lower suspension arm from suspension member.

SA1ZU±01
F11598
SST
F11599
F11593
Wood
F11618
± SUSPENSION AND AXLEREAR SHOCK ABSORBER
SA±51
2001 PRIUS (RM778U)
REMOVAL
1. REMOVE REAR WHEELS
Torque: 103 N´m (250 kgf´cm, 18 ft´lbf)
2. REMOVE REAR SEAT (See page BO±83)
3. DISCONNECT BRAKE LINES
(a) Using SST, disconnect the brake lines from the flexible
hose. Use a container to catch brake fluid as it drains out.
SST 09751±36011
(b) Remove the clip.
(c) Employ the same manner described above to the other
side.
4. DISCONNECT ABS SPEED SENSOR WIRE HARNESS
Remove the 4 nuts, and disconnect the ABS speed sensor wire
harness from the axle beam.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
5. SUPPORT REAR AXLE BEAM AT RIGHT AND LEFT
SIDES WITH JACKS
6. REMOVE SHOCK ABSORBER
(a) Remove the 2 nuts and bolt.
Torque: 80 N´m (816 kgf´cm, 59 ft´lbf)

F11619
SA±52
± SUSPENSION AND AXLEREAR SHOCK ABSORBER
2001 PRIUS (RM778U)
(b) Remove the nut, washer and shock absorber.
Torque: 80 N´m (816 kgf´cm, 59 ft´lbf)

SA1ZV±01
F11600
F11601
SST
F11602
SST
F11603
SA±60
± SUSPENSION AND AXLEREAR AXLE BEAM
2001 PRIUS (RM778U)
REPLACEMENT
1. REMOVE TOE CONTROL LINK
(a) Remove the nut.
(b) Using a brass bar, remove the bolt.
(c) Using a SST, remove the toe control link from axle beam.
SST 09710±40010 (09711±40010, 09712±40010),
09727±30021 (09727±00010, 09727±00031)
NOTICE:

Make sure that the arm inside of SST is contact with
the toe control link at the position shown in the il-
lustration.

Never use SST (09727 ± 00030)
HINT:
The outer race of the toe control link is made of rubber and be-
cause of its elasticity, it is difficult to remove the link from the axle
beam.
So, tap the part indicated by the arrow with a plastic hammer
when removing.
2. INSTALL TOE CONTROL LINK
(a) Using a SST, install a new toe control link.
SST 09710±40010 (09711±40010, 09712±40010),
09727±30021 (09727±00010, 09727±00031)
NOTICE:

Make sure that the arm inside of SST is contact with
the frange of the toe control link.

Align the bolt holes of the toe control link and axle
beam in the direction of press±fitting.
When the bolt holes slip off the aligned position,
press±fit a new toe control link again.
HINT:

Until the outer race is fit into the axle beam, adjust the arm
position of SST to set the toe control link upright to the
axle beam.

When the toe control link is fully press±fit into the axle
beam, the bolt holes are not aligned.

F11604
± SUSPENSION AND AXLEREAR AXLE BEAM
SA±61
2001 PRIUS (RM778U)
(b) Using a extension bar and press, install a new bolt.
NOTICE:
Press in the bolt until the base of the bolt head is pressed
tightly against the axle beam.
(c) Install the a nut.

BR0PX±07
BR±2
± BRAKETROUBLESHOOTING
1517 Author: Date:
2001 PRIUS (RM778U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Low pedal or spongy pedal
5. Fluid leaks for brake system
6. Air in brake system
7. Piston seals (Worn or damaged)
8. Master cylinder (Faulty)
9. Hydraulic brake booster (Faulty)DI±451
BR±4
BR±26
BR±32
BR±16
BR±42
Brake drag
1. Brake pedal freeplay (Minimum)
2. Parking brake pedal travel (Out of adjustment)
3. Parking brake wire (Sticking)
4. Pad or lining (Cracked or distorted)
5. Piston (Stuck)
6. Piston (Frozen)
7. Tension or return spring (Faulty)
8. Hydraulic brake booster (Faulty)BR±7
BR±9
±
BR±23
BR±32
BR±26
BR±32
BR±26
BR±32
BR±32
BR±42
Brake pull
1. Piston (Stuck)
2. Pad or lining (Cracked or distorted)
3. Piston (Frozen)
4. Disc or drum (Scored)
5. Pad or lining (Cracked or distorted)
6. Hydraulic brake booster (Faulty)BR±26
BR±32
BR±23
BR±32
BR±26
BR±32
BR±26
BR±32
BR±23
BR±32
BR±42
Hard pedal but brake inefficient
1. Fluid leaks for brake system
2. Air in brake system
3. Pad or lining (Worn)
4. Pad or lining (Cracked or distorted)
5. Pad or lining (Oily)
6. Pad or lining (Glazed)
7. Disc or drum (Scored)
8. Hydraulic brake booster (Faulty)DI±451
BR±4
BR±23
BR±32
BR±23
BR±32
BR±23
BR±32
BR±23
BR±32
BR±26
BR±32
BR±42

± BRAKETROUBLESHOOTING
BR±3
1518 Author: Date:
2001 PRIUS (RM778U) Noise from brakes
1. Pad or lining (Cracked or distorted)
2. Installation bolt (Loose)
3. Disc or drum (Scored)
4. Pad support plate (Loose)
5. Sliding pin (Worn)
6. Pad or lining (Dirty)
7. Pad or lining (Glazed)
8. Tension or return spring (Faulty)
9. Anti±squeal shim (Damaged)
10.Shoe hold±down spring (Damaged)BR±23
BR±32
BR±26
BR±26
BR±32
BR±23
BR±26
BR±23
BR±32
BR±23
BR±32
BR±32
BR±23
BR±32
Brake warning light lights up*1
(Parking brake pedal released)
1. Brake fluid level
2. Hydraulic brake booster power supply system (Faulty)
BR±41
Brake warning light lights up and brake warning buzzer sounds*2Hydraulic brake booster power supply system (Faulty)BR±41
ABS warning light lights up*31. Anti±lock brake system (Faulty)
2. Hydraulic brake booster power supply system (Faulty)
BR±41
*1, *3: The light may stay on for about 60 seconds after the engine has been started. It is normal if it goes
out after a while.
*
2, *3: Depressing the brake pedal repeatedly may turn on the warning light and buzzer. It is normal if the
light goes out and the buzzer stops sounding after a few seconds.

BR1J6±01
BR±4
± BRAKEBRAKE FLUID
1519 Author: Date:
2001 PRIUS (RM778U)
BRAKE FLUID
BLEEDING
HINT:

If any work is done on the brake system or if air in the
brake lines is suspected, bleed the air from the system.

When bleeding, keep the amount of the fluid within the
line of reservoir between Min. and Max.
NOTICE:

Do not let brake fluid remain on painted surfaces.
Wash it off immediately.

With the reservoir cap removed, when depressing the
brake pedal, the fluid will spray.
1. FILL RESERVOIR WITH BRAKE FLUID
Fluid: SAE J1703 or FMVSS NO. 116 DOT3
2. RELEASE PRESSURE FROM POWER SUPPLY SYS-
TEM
HINT:
If the hydraulic brake booster has been disassembled, discon-
nect the brake line from the hydraulic brake booster or if the res-
ervoir becomes empty, bleed the hydraulic brake booster.
(a) Turn the ignition switch OFF, depress the brake pedal
more than 40 times.
(b) Turn the ignition switch ON, check that the pump stops af-
ter 30 to 40 seconds.
NOTICE:
When the pump does not stop, repeat step (a) and (b) again.
3. BLEED AIR
(a) Turning the ignition switch OFF, bleed the right and left
front brake caliper.
HINT:
Perform air bleeding for each wheel, depress the brake pedal
more than 20 times or more for each.
(b) Turning the ignition switch ON, check that the pump motor
stops.
(c) Fully open the bleeder plug of the right or left rear brake
cylinder and drain the fluid while depressing the brake
pedal for 3 seconds.
HINT:

Perform air bleeding for both wheels on the right or left
side and then do the same on the other side.

It is not necessary to depress the pedal continuously, as
brake fluid flows out by first depressing.
(d) Release the brake pedal and wait until the pump motor
stops.
(e) Repeat step (c) and (d) 7 times or more.
(f) Tighten the bleeder plug of the rear brake cylinder.
Torque: 8.5 N´m (87 kgf´cm, 75 in.´lbf)
(g) While depressing the brake pedal, let air out from the rear
brake cylinder mentioned in (f).

F12396
T
TOYOTA
Hand±held Tester
DLC3
± BRAKEBRAKE FLUID
BR±5
1520 Author: Date:
2001 PRIUS (RM778U)
HINT:

Hold the brake pedal depressed, and it is not necessary
to repeat depressing of the pedal.

Do not continuously drain the fluid from the bleeder plug
for more than 3 seconds.

When closing the bleeder plug, wait until the pump motor
stops if it is operated.

Repeat the procedure until air is completely removed.
(h) Perform step (c) to (g) on the other rear brake cylinder.
(i) With the ignition switch ON, check that the pump motor is
stopped.
(j) Fully the bleeder plug of the front left brake cylinder and
drain the fluid while depressing the brake pedal for 3 se-
conds.
(k) Release the brake pedal and wait until the pump motor
stops.
(l) Repeat step (j) and (k) 4 times.
(m) Tighten the bleeder plug of the front left brake cylinder.
Torque: 8.5 N´m (87 kgf´cm, 75 in.´lbf)
(n) While depressing the brake pedal, let air out from the front
left brake cylinder.
HINT:

Hold the brake pedal depressed, and it is not necessary
to repeat depressing of the pedal.

Do not continuously drain the fluid from the bleeder plug
for more than 3 seconds.

When closing the bleeder plug, wait until the pump motor
stops if it is operated.

Repeat the procedure until air is completely removed.
(o) Check that the pump motor is stopped.
(p) Connect TOYOTA hand±held tester.
(1) Turn the ignition switch OFF, connect the TOYOTA
hand±held tester to DLC3.
(2) Turn the ignition switch ON, and select ºAIR
BLEEDINGº on the TOYOTA hand±held tester.
HINT:
Please refer to the TOYOTA hand±held tester operator's manu-
al for further details.
(q) Holding the brake pedal depressed, turn SRRR solenoid
ON with the TOYOTA hand±held tester.