TOYOTA PRIUS 2001 Service Repair Manual

F12665
Brake Actuator Tube
Clip
Brake Power Supply
Bracket No. 2
Collar
Sleeve Pressure Switch
Assembly
Brake Booster Pump
Bracket No. 1
Cushion Connector Bracket
Washer Silencer TubeSpring Accumulator
Booster Pump Brake Power Supply
Bracket No. 1
Brake Power Supply
Bracket No. 3Brake Booster
Pump Bracket
No. 2Suction Hose
Clip
Collar
Cushion
WasherCushion
Clamp

Non±reusable part: Specified torque
N´m (kgf´cm, ft´lbf)
O±Ring
54 (550, 36)
7.8 (80, 69 in.´lbf)

Clamp
Screw
7.8 (80, 69 in.´lbf)
7.8 (80, 69 in.´lbf)
2.9 (30, 26 in.´lbf)
15 (155, 11)
7.8 (80, 69 in.´lbf)
7.8 (80, 69 in.´lbf)
7.8 (80, 69 in.´lbf)
± BRAKEHYDRAULIC BRAKE BOOSTER
BR±43
2001 PRIUS (RM778U)

BR1JJ±01
F12385
BR±44
± BRAKEHYDRAULIC BRAKE BOOSTER
2001 PRIUS (RM778U)
REMOVAL
NOTICE:
Before starting the work, make sure that the ignition switch
is OFF and depress the brake pedal more than 40 times.
HINT:
When a pressure in power supply system is released, reaction
force becomes heavy.
NOTICE:

As high pressure is applied to the brake actuator
tube, never deform it.

Until the work is over, do not turn the ignition switch
ON.
1. DRAW OUT FLUID WITH SYRINGE
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
2. REMOVE OUTER FRONT COWL TOP PANEL
(See page BO±32)
3. REMOVE RESERVOIR, BRAKE ACTUATOR HOSE,
BRAKE RESERVOIR HOSE NO. 1, NO. 2 AND RES-
ERVOIR BRACKET
(a) Disconnect the fluid level warning switch connector from
the reservoir.
(b) Remove the 2 bolts from the reservoir.
Torque: 7.5 N´m (77 kgf´cm, 66 in.´lbf)
(c) Disconnect the 3 hoses from the reservoir and remove the
reservoir and 3 hoses.
(d) Disconnect the 3 hoses from the reservoir bracket clamp.
(e) Remove the 4 bolts and reservoir bracket.
Torque: 18 N´m (184 kgf´cm, 13 ft´lbf)
4. DISCONNECT LIQUID AND SUCTION TUBES
(a) Disconnect the liquid and suction tubes
(See page AC±25).
(b) Remove the nut and release the liquid and suction tubes.

F12380
SST
Spanner
F12383
 SST
F12381
F12504
F12624
± BRAKEHYDRAULIC BRAKE BOOSTER
BR±45
2001 PRIUS (RM778U)
5. REMOVE RIGHT FRONT BRAKE LINE
(a) Using SST and spanner, disconnect the right front brake
line from the flexible hose and 2 way.
SST 09023±00100
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
(b) Pull out the brake line with the grommet from the body.
6. DISCONNECT BRAKE LINE
Using SST, disconnect the brake line from the hydraulic brake
booster assembly.
SST 09023±00100
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
7. DISCONNECT 2 CONNECTORS
8. REMOVE HYDRAULIC BRAKE BOOSTER ASSEMBLY
(a) Remove the clamp, clamp bracket and 3 bolts.
(b) Release the wire harness to remove the hydraulic brake
booster assembly.

F12625
BR±46
± BRAKEHYDRAULIC BRAKE BOOSTER
2001 PRIUS (RM778U)
(c) Remove the 3 installation bolts and a nut.
Torque: 19 N´m (194 kgf´cm, 14 ft´lbf)
(d) Remove the hydraulic brake booster assembly.
(e) Remove the 2 bolts and sub±bracket.
Torque: 19 N´m (194 kgf´cm, 14 ft´lbf)

BR1JL±01
F12503
F08657
SST
SST
BoltBolt
F12076
BR±56
± BRAKEREAR SPEED SENSOR
2001 PRIUS (RM778U)
REMOVAL
1. REMOVE REAR WHEEL
2. DISCONNECT SPEED SENSOR CONNECTOR
Disconnect the connector from the speed sensor.
3. REMOVE SPEED SENSOR WITH REAR AXLE HUB
(See page SA±46)
4. REMOVE SPEED SENSOR
(a) Using a pin punch and hammer, drive out the 2 pins and
remove the 2 attachments from SST.
SST 09520±00031
(b) Mount the rear axle hub in a soft jaw vise.
NOTICE:
Replace the axle hub assembly if it is dropped or a strong
shock is given to it.
(c) Using SST and 2 bolts (Diameter: 12 mm, Pitch: 1.5 mm),
remove the speed sensor.
SST 09520±00031 (09520±00040, 09521±00020),
09950±00020
NOTICE:

If a damage is inflicted to the sensor rotor, replace the
axle hub assembly.

Do not scratch the contacting surface of axle hub and
speed sensor.
5. IF NECESSARY, REPLACE SPEED SENSOR WIRE
HARNESS
(a) Remove the seat cushion, seatback and quarter trim
(See page BO±83).
(b) Disconnect the speed sensor wire harness connector.

± BRAKEREAR SPEED SENSOR
BR±57
2001 PRIUS (RM778U)
(c) Remove the 2 bolts, 2 nuts holding the sensor harness
from the lower arm and body.
Torque: 5.5 N´m (56 kgf´cm, 49 in.´lbf)
(d) Replace the sensor wire harness with the grommet.

SR08F±07
± STEERINGSTEERING SYSTEM
SR±1
1574 Author: Date:
2001 PRIUS (RM778U)
STEERING SYSTEM
PRECAUTION

Care must be taken to replace parts properly because they could affect the performance of the
steering system and result in a driving hazard.

The PRIUS is equipped with SRS (Supplemental Restraint System) such as the driver airbag
and passenger airbag. Failure to carry out service operation in the correct sequence could
cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident.
Before servicing (including removal or installation of parts, inspection or replacement), be sure
to read the precautionary notices in the RS section.

SR1BE±01
F12219
Shift Lever Assembly
Upper Column Cover
Lower Ciolumn CoverSteering Wheel Pad
Steering Wheel
Combination Switch
(w/ Spiral Cable)
Transmission Control
Cable Steering Column
Assembly
Shift Lock Computer
Sub±assembly Sliding Yoke
No. 2 Intermediate
Shaft Assembly
Column Hole Cover
Main Shaft Lower
Dust Seal
Hood Lock
Release LeverLower Instrument
Finish Panel
N´m (kgf´cm, ft´lbf): Specified torque
35 (360, 26)
25 (260, 19)
49 (50, 43 in.´lbf)
35 (360, 26)
35 (360, 26)
25 (260, 19)
50 (510, 37)
8.8 (90, 78 in.´lbf)
Torx Screw
8.0 (80, 69 in.´lbf)
8.8 (90, 78 in.´lbf)
Torx Screw
4.0 (40, 35 in.´lbf)
Instrument Finish
Panel
49 (50, 43 in.´lbf)
SR±4
± STEERINGTILT STEERING COLUMN
1577 Author: Date:
2001 PRIUS (RM778U)
TILT STEERING COLUMN
COMPONENTS

F12238
Transponder Key Coil
Column Upper BracketKey Cylinder
Column Upper Clamp Key Unlock
Warning Switch
Tapered±head Bolt Ignition Switch Break Away Capsule
Energy Absorbing
Plate
Energy Absorbing
Plate Guide Energy Absorbing
Clip
Tilt Lever Lock BoltBreak Away Bracket
Snap Ring
Column Tube
Sub±assembly
Tilt Lever
No. 1 Tilt Steering
Support Reinforce Tilt Steering
Adjust Nut
Torsion Spring Steering Pawl Set Bolt No. 1 Tilt Steering
Support Collar Tilt Steering Support
Washer
Main Shaft Assembly





Energy Absorbing
Plate


Snap Ring


Tilt Sub Lever
Main Shaft Bushing
13 (130, 9)
9.5 (100, 87 in.´lbf)
5.4 (55, 48 in.´lbf)
N´m (kgf´cm, ft´lbf): Specified torque
Non±reusable part
Key Interlock Solenoid
No. 2
Tilt Lever
Lock Bolt
Molybdenum disulfide lithium base grease
± STEERINGTILT STEERING COLUMN
SR±5
1578 Author: Date:
2001 PRIUS (RM778U)

SR1BF±01
F12211
Torx
ScrewTorx Screw
Case
F12212
Correct WrongAirbag Connector
F12213SST
Matchmarks
SR±6
± STEERINGTILT STEERING COLUMN
2001 PRIUS (RM778U)
REMOVAL
1. REMOVE STEERING WHEEL PAD
NOTICE:
If the airbag connector is disconnected with the ignition
switch at ON, DTCs will be recorded.
(a) Place the front wheels facing straight ahead.
(b) Using a torx socket wrench, loosen the 2 torx screws until
the groove along the screw circumference catches on the
screw case.
(c) Pull out the wheel pad from the steering wheel and dis-
connect the airbag connector.
(d) Disconnect the connector.
CAUTION:

When storing the wheel pad, keep the upper surface
of the pad facing upward.

Never disassemble the wheel pad.
NOTICE:
When removing the wheel pad, take care not to pull the air-
bag wire harness.
2. REMOVE STEERING WHEEL
(a) Remove the steering wheel set nut.
(b) Place matchmarks on the steering wheel and main shaft
assembly.
(c) Using SST, remove the steering wheel.
SST 09950±50012 (09951±05010, 09952±05010,
09953±05020, 09954±05020)