wheel torque TOYOTA PRIUS 2001 Service User Guide

P21235
MA049±01
F12933
F12919
MA±8
± MAINTENANCEBODY
61 Author: Date:
2001 PRIUS (RM778U)
BODY
INSPECTION
1. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY
Tighten these parts:

Front seat mount bolts
Torque: 37 N´m (375 kgf´cm, 27 ft´lbf)

Front suspension member±to±body mounting bolts
Torque:
Bolt A: 113 N´m (1,150 kgf´cm, 83 ft´lbf)
Bolt B: 157 N´m (1,600 kgf´cm, 116 ft´lbf)

Rear suspension member±to±body mounting nuts
Torque: 90 N´m (918 kgf´cm, 66 ft´lbf)
2. FINAL INSPECTION
(a) Check the operation of the body parts:

Hood:
Auxiliary catch operate properly
Hood locks securely when closed

Front and rear doors:
Door lock operates properly
Doors close properly

Luggage compartment door:
Door lock operates properly

Seats:
Seat adjusts easily and locks securely in any posi-
tion
Front seat back locks securely in any position
Folding±down rear seat backs lock securely
(b) Road test:

Check the engine and chassis for abnormal noises.

Check that the vehicle does not wander or pull to
one side.

Check that the brake work properly and do not drag.
(c) Be sure to deliver a clean car. especially check:

Steering wheel

Shift lever knob

All switch knobs

Door handles

Seats

PP0T0±01
± PREPARATIONSUPPLEMENTAL RESTRAINT SYSTEM
PP±47
2001 PRIUS (RM778U)
EQUIPMENT
Torque wrench
Bolt: Length: 35 mm (1.38 in.) Pitch: 1.0 mm (0.039 in.)
Diam: 6.0 mm (0.236 in.)Airbag disposal
Tire Width: 185 mm (7.28 in.) Inner diam: 360 mm (14.17 in.)Airbag disposal
Tire with disc wheel Width: 185 mm (7.28 in.)
Inner diam: 360 mm (14.17 in.)Airbag disposal
Vinyl bagAirbag disposal

PP3B1±01
PP±54
± PREPARATIONBODY
2001 PRIUS (RM778U)
EQUIPMENT
Clip remover
Torque wrench
Hexagon wrench (6 mm)
Torx driver
Hog ring pliers
Hand riveter
TapeTo avoid surface damage
Adhesive tapeTo avoid surface damage
Double±stick tape
Adhesive
Cleaner
Shop rag
Knife
Sealer gun
Brush
Putty spatula
Glass plate or similar object
Wooden block or similar object
Heat light
Piano wire
Rope (no projections, difficult to break)Seat belt pretensioner
Tire with disk wheel Width: 185 mm (7.28 in.)
Inner diam: 360 mm (14.17 in.)Seat belt pretensioner
Vinyl bagSeat belt pretensioner

SS175±03
SS±10
± SERVICE SPECIFICATIONSENGINE MECHANICAL
2001 PRIUS (RM778U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Plug x Timing chain cover1515011
Chain vibration damper x Cylinder block9.09280 in .´lbf
Chain tensioner9.09280 in .´lbf
Timing chain cover Bolt A
Bolt B
Bolt C
Bolt D
Bolt E
Nut F
Nut G11
24
11
24
11
24
1111 2
245
11 2
245
11 2
245
11 28
18
8
18
8
18
8
RH engine mounting bracket x Timing chain cover5556141
Crankshaft position sensor x Timing chain cover Bolt A
Bolt B7.5
1176
11 266 in .´lbf
8
Oil control valve8.08271 in .´lbf
Crankshaft pulley x Crankshaft1281,30094
Cylinder head cover x Cylinder101007
RH engine mounting insulator Bolt A
Bolt B
Nut45
52
52459
530
53033
38
38
Cylinder head x Cylinder block 1st
2nd
3rd29.4
Turn 90°
Turn 90°300
Turn 90°
Turn 90°22
Turn 90°
Turn 90°
Water bypass pipe x Cylinder head9.09280 in .´lbf
No. 1 camshaft bearing cap x Cylinder head2323517
No. 2 camshaft bearing cap x Cylinder head12.713010
Camshaft timing sprocket x Camshaft6465047
Valve timing controller assembly x Camshaft6465047
Intake manifold x Cylinder head2020415
Exhaust manifold x Cylinder head2727520
Upper heat insulator x Exhaust manifold8.08271 in .´lbf
Exhaust manifold stay x Cylinder block2727520
Front exhaust pipe x Tailpipe Bolt A
Bolt B62
32630
33046
24
Connecting rod cap x Connecting rod 1st
2nd15
Turn 90°150
Turn 90°11
Turn 90°
Bearing cap x Cylinder block 1st
2nd22
Turn 90°220
Turn 90°16
Turn 90°
Oil pan No. 1 x Cylinder block2424518
Oil strainer x Oil pan No. 11111 28
Oil pan No. 2 x Oil pan No. 19.09280 in.´lbf
Oil filter union x Oil pan No. 13030621
Engine coolant drain plug x Cylinder block12.71309
Knock sensor x Cylinder block4445033
Water bypass pipe x Cylinder block9.09080 in.´lbf
Flywheel x Crankshaft8485762
Damper spring x Flywheel1616312

SS13W±06
SS±26
± SERVICE SPECIFICATIONSSUSPENSION AND AXLE
148 Author: Date:
2001 PRIUS (RM778U)
SUSPENSION AND AXLE
SERVICE DATA
Cold tire inflation
pressureTire size: P175/65R14 84S Front
Rear240 kPa (2.4 kgf/cm2, 35 psi)
230 kPa (2.3 kgf/cm2, 33 psi)
Vehicle height
P175/65R14Front*1
Rear*2191 mm (7.52 in.)
239 mm (9.41 in.)
Camber
Right±left error±0°26' ± 45' (±0.43° ± 0.75°)
45' (0.75°) or less
Front wheel
Caster
Right±left error1°02' ± 45' (1.03° ± 0.75°)
45' (0.75°) or less
Front wheel
alignmentSteering axis inclination
Right±left error9°52' ± 45' (9.87° ± 0.75°)
45' (0.75°) or less
Toe±in (total)
Rack end length difference0°06' ± 12' (0.1° ± 0.2°, 1 ± 2 mm, 0.04± 0.08 in.)
1.5 mm (0.059 in.) or less
Wheel angle
Inside wheel
Outside wheel: Reference
42°42' ± 2° (42.70° ± 2°)
35°54' (35.90°)
Rear wheel
Camber
Right±left error±1°30' ± 45' (±0.93° ± 0.75°)
45' (0.75°) or less
Rear wheel
alignmentToe±in (total)0°06' ± 20' (0.1° ± 0.33°)
1 ± 3.0 mm (0.04 ± 0.12 in.)
FtlAxle bearing backlash Maximum0.05 mm (0.0020 in.)Front axleAxle hub deviationMaximum0.07 mm (0.0028 in.)
Front drive shaftDrive shaft standard length LH
RH579.9 ± 5.0 mm (22.831 ± 0.197 in.)
836.9 ± 5.0 mm (32.949 ± 0.197 in.)
Ft iLower suspension arm ball joint turning torque1.0 ± 4.9 N´m (10 ± 50 kgf´cm, 8.7 ± 43 in.´lbf)Front suspensionStabilizer bar link ball joint turning torque0.05 ± 1.0 N´m (0.5 ± 10 kgf´cm, 0.4 ± 8.7 in.´lbf)
RlAxle bearing backlash Maximum0.05 mm (0.0020 in.)Rear axleAxle hub deviationMaximum0.07 mm (0.0028 in.)
*1: Front measuring point
Measure the distance from the ground to the head center of the front side lower suspension arm mounting
bolt.
*2: Rear measuring point
Measure the distance from the ground to the center of the rear axle beam mounting bolt.

SS0LN±06
± SERVICE SPECIFICATIONSBRAKE
SS±29
2001 PRIUS (RM778U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
BRAKE PEDAL
Pedal bracket x Reinforcement1414310
Brake pedal x Pedal bracket3737527
PARKING BRAKE PEDAL
Pedal bracket x Reinforcement1414310
Pedal bracket x Body131309
Brake pedal x Pedal bracket3232724
BRAKE MASTER CYLINDER
Master cylinder x Pedal bracket131309
Master cylinder clevis lock nut2626519
HYDRAULIC BRAKE BOOSTER
Hydraulic brake booster assembly x Body1919414
Sub±bracket x Body1919414
Reservoir bracket x Body1818413
Reservoir x Bracket7.57766 in.´lbf
Accumulator x Booster pump5455036
Pressure switch assembly x Brake power supply bracket7.88069 in.´lbf
Booster pump x Brake booster pump bracket No. 27.88069 in.´lbf
Pressure switch assembly x Brake booster pump bracket No. 17.88069 in.´lbf
Connector bracket x Pressure switch assembly7.88069 in.´lbf
Pressure switch assembly x Brake booster pump bracket No. 27.88069 in.´lbf
FRONT BRAKE
Front disc brake caliper installation bolt3435025
Bleeder plug8.38574 in.´lbf
Front disc brake caliper x Flexible hose3031022
Front disc brake torque plate x Steering knuckle1071,09079
REAR BRAKE
Bleeder plug8.58775 in.´lbf
Rear drum brake wheel cylinder x Backing plate101007
BRAKE ACTUATOR
Brake actuator assembly x Body1919514
Brake actuator x Actuator bracket111208
SPEED SENSOR
Front speed sensor installation bolt8.08271 in.´lbf
Front speed sensor harness clamp bolt5.55649 in.´lbf
Rear speed sensor harness clamp bolt5.55649 in.´lbf
BRAKE LINE
Brake line union nut1515511

SS16Z±08
± SERVICE SPECIFICATIONSSTEERING
SS±31
2001 PRIUS (RM778U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
TILT STEERING COLUMN
Adjusting nut131309
No. 2 tilt lever lock bolt5.45548 in.´lbf
Tilt steering support lock nut9.510087 in.´lbf
Main shaft lower dust seal4.95043 in.´lbf
Column assembly set bolt and nut2526019
No. 2 intermediate shaft assembly x Main shaft assembly3536026
No. 2 intermediate shaft assembly x Intermediate extension3536026
Shift lock computer sub±assembly4.04035 in.´lbf
Steering wheel set nut5051037
Steering wheel pad set screw (Torx screw)8.89078 in.´lbf
POWER STEERING GEAR
Rack end x Steering rack62 (83)630 (850)46 (61)
Tie rod end lock nut5657041
PS gear assembly set bolt8385061
Stabilizer bar set bolt1919014
Suspension member137
1421,400
1,450101
105
Torque rod set nut1001,02074
EMPS bracket set bolt5.56052 in.´lbf
Lower suspension arm x Lower ball joint1421,450105
Stabilizer bar link set nut7476055
Tie rod end x Steering knuckle4950036
( ): For use without SST

F12396
TOYOTA
Hand±held Tester
DLC3
DI±462
± DIAGNOSTICSELECTRIC MOTOR POWER STEERING
2001 PRIUS (RM778U)
(b) In case of using TOYOTA hand±held tester:
Check the input signal.
(1) Hook up the TOYOTA hand±held tester to the
DLC3.
(2) Check the warning light goes off with driving more
than 20 km/h (12 mph).
(3) Read the DTC by following the prompts on the tes-
ter screen.
HINT:

Please refer to the TOYOTA hand±held tester operator's
manual for further details.

See the list of DTC shown on the bottom of this page.

Even a sensor is normal, it output codes 71 and 72 during
test mode.
DTC of input signal check function:
Code No.
(See page)DiagnosisTrouble Area
C1515/15
(DI±468)Calibration of torque sensor zero point Not Performed±
C1516/16
(DI±469)Calibration of torque sensor zero point Not completed±
C1571/71
C1572/72
(DI±474)
Speed sensor malfunction (Test mode)

Right rear or left rear speed sensor

Sensor installation

Right rear or left rear speed sensor rotor

Right rear or left rear speed sensor circuit

Brake ECU

EMPS ECU
3. CALIBRATION OF TORQUE SENSOR ZERO POINT
HINT:
Perform this operation in the following cases.

When removing and installing ºsteering wheelº, ºtilt steer-
ing columnºand ºelectric power steering gearº.

When replacing EMPS ECU.
(a) Place front wheels and steering wheel facing straight
ahead.
(b) In case of using TOYOTA hand±held tester:
Perform the torque sensor zero point initialization.
HINT:
If the EMPS ECU is replaced, however, this operation is not
necessary.
(1) Stop the vehicle.

F12396
TOYOTA
Hand±held Tester
DLC3
F12827
Tc
CG
Ts
F12864
Tc
CG
± DIAGNOSTICSELECTRIC MOTOR POWER STEERING
DI±463
2001 PRIUS (RM778U)
(2) Hook up the TOYOTA hand±held tester to the
DLC3.
(3) Select the ºTRQ SENS ADJUSTº mode on the TOY-
OTA hand±held tester.
(4) Select the ºZERO POINT INITIALIZEº.
(5) Following the screen instructions, perform the
torque sensor zero point initialization.
HINT:
Please refer to the TOYOTA hand±held tester operator's manu-
al for further details.
(c) In case of not using TOYOTA hand±held tester:
Perform the torque sensor zero point initialization.
HINT:
If the EMPS ECU is replaced, however, this operation is not
necessary.
(1) Stop the vehicle.
(2) Using SST, connect terminals Ts and CG of DLC3.
SST 09843±18040
(3) Using SST, connect terminals Tc and CG of DLC3.
SST 09843±18040
(4) ON and OFF the terminal Tc of DLC3 20 times within
20 sedonds.
(5) Check that the DTC C1515/15.
(d) In case of using TOYOTA hand±held tester:
Perform the torque sensor zero point calibration.
HINT:
Don't touch the steering wheel.
(1) Select the ºTRQ SENS ADJUSTº mode on the TOY-
OTA hand±held tester.
(2) Select the ºZERO POINT ADJUSTº.
(3) Following the screen instructions, perform the
torque sensor zero point calibration.
HINT:
Please refer to the TOYOTA hand±held tester operator's manu-
al for further details.
(e) In case of not using TOYOTA hand±held tester:
Perform the torque sensor zero point calibration.
HINT:

Don't touch the steering wheel.

Check the DTC except C1515/15 is not output.
(1) Stop the vehicle and turn the ignition switch OFF.

A13906
N´m (kgf´cm, ft´lbf) : Specified torque
16 (163, 12)
Engine Unit
Fly Wheel
x6Damper Disc
x6 Damper Disc Spring
Transaxle
Non±reusable part



49 (500, 36)
See page EM±58 1st:
2nd: 90°
33 (337, 24)
EM±52
± ENGINE MECHANICALENGINE UNIT
1168 Author: Date:
2001 PRIUS (RM778U)