TOYOTA PRIUS 2001 Service Repair Manual

F12830
F12214
Matchmarks
A
B
± STEERINGTILT STEERING COLUMN
SR±7
2001 PRIUS (RM778U)
3. REMOVE LOWER INSTRUMENT FINISH PANEL
(a) Remove the 2 screws and disconnect hood lock release
lever.
(b) Remove the screw and bolt.
(c) Disconnect the connectors and DLC3, and remove the
lower instrument finish panel.
4. REMOVE UPPER AND LOWER COLUMN COVERS
(a) Remove the 3 screws and lower column cover.
(b) Remove the screw and upper column cover.
5. REMOVE COMBINATION SWITCH WITH SPIRAL
CABLE
(a) Disconnect the connectors.
(b) Disconnect the airbag connector.
(c) Remove the 3 screws and combination switch with spiral
cable.
6. REMOVE SPIRAL CABLE (See page BE±19)
NOTICE:
Do not disassemble the spiral cable or apply oil to it.
7. DISCONNECT TRANSMISSION CONTROL CABLE
8. REMOVE SHIFT LEVER ASSEMBLY
(See page HT±50)
9. DISCONNECT COLUMN HOLE COVER
Remove the 3 clips and disconnect the column hole cover.
10. REMOVE SHIFT LOCK COMPUTER SUB±ASSEMBLY
Remove the screw and shift lock computer sub±assembly.
11. DISCONNECT NO. 2 INTERMEDIATE SHAFT AS-
SEMBLY
(a) Place matchmarks on the No. 2 intermediate shaft as-
sembly and control valve shaft.
(b) Loosen the bolt ºAº and remove the bolt ºBº, then discon-
nect the No. 2 intermediate shaft assembly from the con-
trol valve shaft.
12. REMOVE INSTRUMENT FINISH PANEL
Remove the 3 screws and instrument finish panel.
13. REMOVE STEERING COLUMN ASSEMBLY
(a) Disconnect the connectors.
(b) Remove the 2 bolts, 2 nuts and steering column assem-
bly.
14. REMOVE NO. 2 INTERMEDIATE SHAFT ASSEMBLY
Remove the bolt and No. 2 intermediate shaft assembly from
the sliding yoke.
15. REMOVE SLIDING YOKE
Remove the bolt and sliding yoke from the main shaft assembly.
16. REMOVE COLUMN HOLE COVER

F12215
SR±8
± STEERINGTILT STEERING COLUMN
2001 PRIUS (RM778U)
17. REMOVE MAIN SHAFT LOWER DUST SEAL
(a) Remove the 2 nuts and parking brake cable bracket.
(b) Remove the 2 bolts and disconnect the accelerator pedal.
(c) Remove the 3 nuts and main shaft lower dust seal.

SR1BG±01
F12223Screw Extractor
F12235
F12225
± STEERINGTILT STEERING COLUMN
SR±9
2001 PRIUS (RM778U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. REMOVE TRANSPONDER KEY COIL
Remove the screw and transponder key coil.
2. REMOVE COLUMN UPPER BRACKET AND COLUMN
UPPER CLAMP
(a) Using a centering punch, mark the center of the 2 ta-
pered±head bolts.
(b) Using a 3 ± 4 mm (0.12 ± 0.16 in.) drill, drill into the 2 bolts.
(c) Using a screw extractor, remove the 2 bolts, column up-
per bracket and column upper clamp.
3. REMOVE TILT STEERING SUPPORT
(a) Remove the look nut.
(b) Remove the washer, steering pawl set bolt and tilt steer-
ing support.
(c) Remove the 2 No. 1 tilt steering support collars.
4. REMOVE 2 ENERGY ABSORBING PLATES
(a) Using pliers, remove the 2 energy absorbing clips.
(b) Remove the 2 energy absorbing plates, 2 energy absorb-
ing guides, and 2 break away capsules.
5. REMOVE TORSION SPRING
Using a screw driver, remove the torsion spring.

F12226
F12227
F12228
SR±10
± STEERINGTILT STEERING COLUMN
2001 PRIUS (RM778U)
6. REMOVE TILT LEVER AND BREAK AWAY BRACKET
(a) Remove No. 2 tilt lever lock bolt and No. 1 tilt steering sup-
port reinforce.
HINT:
This bolt is left±handed one.
(b) Remove the tilt steering adjusting nut, tilt lever, tilt sub le-
ver, tilt lever lock bolt and break away bracket.
HINT:
This bolt is left±handed one.
7. REMOVE MAIN SHAFT ASSEMBLY AND MAIN SHAFT
BUSHING
(a) Using a snap ring expander, remove the snap ring on the
upper side.
(b) Using a brass bar and a hammer, tap out the main shaft
assembly with the main shaft bushing.
(c) Remove the main shaft bushing.
(d) Using a snap ring expander, remove the snap ring on the
lower side.

SR1BI±01
F12231
SST
F12232
SR±12
± STEERINGTILT STEERING COLUMN
2001 PRIUS (RM778U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT PARTS INDICATED BY ARROWS WITH MOLYB-
DENUM DISULFIDE LITHIUM BASE GREASE (See
page SR±4)
2. INSTALL MAIN SHAFT ASSEMBLY
(a) Using a snap ring expander, install a new snap ring on the
lower side.
(b) Install the main shaft assembly.
(c) Using a snap ring expander, install a new snap ring on the
upper side.
3. INSTALL MAIN SHAFT BUSING
(a) Coat a new bushing with molybdenum disulfide lithium
base grease.
(b) Using SST and a hammer, tap in the main shaft bushing.
SST 09608±06041
4. INSTALL BREAK AWAY BRACKET AND TILT LEVER
(a) Install break away bracket, tilt lever lock bolt, tilt sub lever
and tilt lever.
HINT:
Align the holes in the break away bracket with the projections
of the tilt lever lock bolt and tilt sub lever.
(b) Install the tilt steering adjusting nut by rotating it counter-
clockwise.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)

F12233
F12234
F12236
F12224
± STEERINGTILT STEERING COLUMN
SR±13
2001 PRIUS (RM778U)
(c) Install the No. 1 tilt steering support reinforce with the No.
2 tilt lever lock bolt by turning it counterclockwise.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
HINT:
Align the No. 1 support reinforce with the nut to eliminate loose-
ness by turning the No. 1 support reinforce counterclockwise a
little, then torque the No. 2 tilt lever lock bolt.
5. INSTALL TORSION SPRING
6. INSTALL 2 ENERGY ABSORBING PLATES
(a) Install the 2 break away capsules, 2 energy absorbing
guides and 2 energy absorbing plates.
(b) Install the 2 new energy absorbing clips.
7. INSTALL TILT STEERING SUPPORT
(a) Install the 2 No. 1 tilt steering support collars.
(b) Install the tilt steering support, steering pawl set bolt,
washer.
(c) Install the lock nut.
Torque: 9.5 N´m (100 kgf´cm, 87 in.´lbf)
8. INSTALL COLUMN UPPER BRACKET AND COLUMN
UPPER CLAMP
(a) Install the column upper bracket and column upper clamp
with 2 new tapered±head bolts.
(b) Tighten the 2 tapered±head bolts until the bolt heads
break off.

SR1BJ±01
F12215
F12214
Matchmarks
A
B SR±14
± STEERINGTILT STEERING COLUMN
2001 PRIUS (RM778U)
INSTALLATION
1. INSTALL MAIN SHAFT LOWER DUST SEAL
(a) Install the main shaft lower dust seal with the 3 nuts.
Torque: 4.9 N´m (50 kgf´cm, 43 in.´lbf)
(b) Connect the accelerator pedal with the 2 bolts.
(c) Install the parking brake cable bracket with the 2 nuts.
2. INSTALL COLUMN HOLE COVER
3. INSTALL SLIDING YOKE
Install the sliding yoke to the main shaft assembly with the bolt.
Torque: 35 N´m (360 kgf´cm, 26 ft´lbf)
4. INSTALL NO. 2 INTERMEDIATE SHAFT ASSEMBLY
Temporarily install the No. 2 intermediate shaft assembly to the
sliding yoke with the bolt.
5. INSTALL STEERING COLUMN ASSEMBLY
(a) Install the steering column assembly with the 2 bolts and
2 nuts.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
(b) Connect the connectors.
6. INSTALL INSTRUMENT FINISH PANEL
Install the instrument finish panel with the 3 screws.
7. CONNECT NO. 2 INTERMEDIATE SHAFT ASSEMBLY
(a) Align the matchmarks on the No. 2 intermediate shaft as-
sembly and control valve shaft.
(b) Install the bolt ºBº and torque the bolt ºAº.
Torque: 35 N´m (360 kgf´cm, 26 ft´lbf)
8. INSTALL SHIFT LOCK COMPUTER SUB±ASSEMBLY
Install the shift lock computer sub±assembly with the screw.
9. CONNECT COLUMN HOLE COVER
Connect the column hole cover with the 3 clips.
10. INSTALL SHIFT LEVER ASSEMBLY
(See page HT±52)

F12830
F08459
Marks
± STEERINGTILT STEERING COLUMN
SR±15
2001 PRIUS (RM778U)
11. CONNECT TRANSMISSION CONTROL CABLE
12. INSTALL SPIRAL CABLE (See page BE±19)
13. INSTALL COMBINATION SWITCH WITH SPIRAL
CABLE
(a) Install the combination switch with spiral cable with the 3
screws.
(b) Connect the airbag connector.
(c) Connect the connectors.
14. INSTALL UPPER AND LOWER COLUMN COVERS
(a) Install the upper column cover with the screw.
(b) Install the lower column cover with the 3 screws.
15. INSTALL LOWER INSTRUMENT FINISH PANEL
(a) Connect the connectors and DLC3 and install the lower
instrument finish panel.
(b) Install the screw and bolt.
(c) Connect the hood lock release lever with the 2 screws.
16. CENTER SPIRAL CABLE
(a) Check that the front wheels are facing straight ahead.
(b) Turn the cable counterclockwise by hand until it becomes
harder to turn.
(c) Then rotate the cable clockwise about 2.5 turns to align
the marks.
HINT:
The cable will rotate about 2.5 turns to either left or right of the
center.
17. INSTALL STEERING WHEEL
(a) Align the matchmarks on the steering wheel and main
shaft assembly.
(b) Install the steering wheel set nut.
Torque: 50 N´m (510 kgf´cm, 37 ft´lbf)
18. INSTALL STEERING WHEEL PAD
NOTICE:

Never use airbag parts from another vehicle. When
replacing parts, replace with new ones.

Make sure the wheel pad is installed with the speci-
fied torque.

If the wheel pad has been dropped, or there are
cracks, dents or other defects in the case or connec-
tor, replace the wheel pad with a new one.

When installing the wheel pad, take care that the wir-
ings do not interfere with other parts and that they are
not pinched between other parts.
(a) Connect the connector.
(b) Connect the airbag connector.

F12217
Torx ScrewTorx Screw
Case
SR±16
± STEERINGTILT STEERING COLUMN
2001 PRIUS (RM778U)
(c) Install the steering wheel pad after confirming that the cir-
cumference groove of the torx screws is caught on the
screw case.
(d) Using a torx socket wrench, torque the 2 screws.
Torque: 8.8 N´m (90 kgf´cm, 78 in.´lbf)
19. CHECK STEERING WHEEL CENTER POINT
20. PERFORM CALIBRATION OF TORQUE SENSOR
ZERO POINT (See page DI±454)

SR1BK±01
F12851
No. 2 Intermediate Shaft Assembly

Cotter Pin
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part
74 (760, 55)
35 (360, 26)
83 (850, 61)
49 (500, 36)

Cotter PinElectric Power
Steering Gear Assembly
Rack Housing
No. 2 Grommet
Rack Housing
No. 2 Bracket
83 (850, 61)
83 (850, 61)
74 (760, 55)
19 (190, 14)
19 (190, 14)Stabilizer Bar
142 (1450, 105)
142 (1,450, 105)
100 (1,020, 74)
137 (1,400, 101)
137 (1,400, 101)142 (1,450, 105)
137 (1,400, 101)
Suspension Member
LH Engine Under Cover
LH Engine Under Cover
49 (500, 36)
137 (4,400, 101)
Torque Rod
5.5 (60, 52 in.´lbf)5.5 (60, 52 in.´lbf)
EMPS Bracket





± STEERINGELECTRIC POWER STEERING GEAR
SR±17
1590 Author: Date:
2001 PRIUS (RM778U)
ELECTRIC POWER STEERING GEAR
COMPONENTS