steering wheel TOYOTA PRIUS 2001 Service Owner's Manual

MA02F±02
MA±2
± MAINTENANCEINSIDE VEHICLE
55 Author: Date:
2001 PRIUS (RM778U)
INSIDE VEHICLE
GENERAL MAINTENANCE
These are maintenance and inspection items which are considered to be the owner's responsibility.
They can be done by the owner or they can have them done at a service shop.
These items include those which should be checked on a daily basis, those which, in most cases, do not
require (special) tools and those which are considered to be reasonable for the owner to do.
Items and procedures for general maintenance are as follows.
1. GENERAL NOTES

Maintenance items may vary from country to country. Check the owner's manual supplement in which
the maintenance schedule is shown.

Every service item in the periodic maintenance schedule must be performed.

Periodic maintenance service must be performed according to whichever interval in the periodic main-
tenance schedule occurs first, the odometer reading (miles) or the time interval (months).

Maintenance service after the last period should be performed at the same interval as before unless
otherwise noted.
2. LIGHTS
(a) Check that the headlights, stop lights, taillights, turn signal lights, and other lights are all working.
(b) Check the headlight aim.
3. WARNING LIGHTS AND BUZZERS
Check that all warning lights and buzzers function properly.
4. HORN
Check that it is working.
5. WINDSHIELD GLASS
Check for scratches, pits or abrasions.
6. WINDSHIELD WIPER AND WASHER
(a) Check operation of the wipers and washer.
(b) Check that the wipers do not streak.
7. WINDSHIELD DEFROSTER
Check that air comes out from the defroster outlet when operating the heater or air conditioner.
8. REAR VIEW MIRROR
Check that it is mounted securely.
9. SUN VISORS
Check that they move freely and are mounted securely.
10. STEERING WHEEL
Check that it has the specified freeplay. Be alert for changes in steering condition, such as hard steering,
excessive freeplay or strange noises.
11. SEATS
(a) Check that the seat adjusters operate smoothly.
(b) Check that all latches lock securely in any position.
(c) Check that the head restraints move up and down smoothly and that the locks hold securely in any
latch position.
(d) For fold±down seat backs, check that the latches lock securely.
12. SEAT BELTS
(a) Check that the seat belt system such as the buckles, retractors and anchors operate properly and
smoothly.
(b) Check that the belt webbing is not cut, frayed, worn or damaged.

MA048±01
S01303
Dust Cover
± MAINTENANCECHASSIS
MA±7
60 Author: Date:
2001 PRIUS (RM778U)
CHASSIS
INSPECTION
1. INSPECT STEERING LINKAGE
(a) Check the steering wheel freeplay. (See page SR±3)
(b) Check the steering linkage for looseness or damage.
Check that:

Tie rod ends do not have excessive play.

Dust seals and boots are not damaged.

Boot clamps are not loose.
2. INSPECT SRS AIRBAG (See page RS±2)
3. INSPECT STEERING GEAR HOUSING OIL
Check the steering gear housing for oil leakage.
4. INSPECT DRIVE SHAFT BOOTS
Check the drive shaft boots for clamp looseness, leakage or
damage.
5. INSPECT BALL JOINTS AND DUST COVERS
(a) Inspect the ball joints for excessive looseness.

Jack up the front of the vehicle and place wooden
blocks with a height of 180 ± 200 mm (7.09 ± 7.87
in.) under the front tires.

Lower the jack until there is about half a load on the
front coil spring. Place stands under the vehicle for
safety.

Check that the front wheels are pointing straight
ahead, and block them with chocks.

Using a lever, pry up the end of the lower arm, and
check the amount of play.
Maximum ball joint vertical play: 0 mm (0 in.)
If there is play, replace the ball joint.
(b) Check the dust cover for damage.
6. CHECK TRANSAXLE OIL (FLUID)
Visually check the transaxle for oil (fluid) leakage.
If leakage is found, check for the cause and repair.
7. REPLACE TRANSAXLE OIL (FLUID)
Replace the transaxle oil (See page HT±26).

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

PP26D±02
± PREPARATIONBODY ELECTRICAL
PP±49
2001 PRIUS (RM778U)
RECOMMENDED TOOLS
09082±00040TOYOTA Electrical Tester.
09041±00030Torx Driver T30 .Steering wheel pad
09042±00010Torx Socket T30 .Steering wheel pad

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

SS16Y±09
SS±30
± SERVICE SPECIFICATIONSSTEERING
152 Author: Date:
2001 PRIUS (RM778U)
STEERING
SERVICE DATA
STEERING WHEEL
Steering wheel freeplayMaximum30 mm (1.18 in.)
Steering effort at idle speedReference6.5 N´m (65 kgf´cm, 58 in.´lbf)

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
F09750
DLC3Tc
Ts
CG
BR3904
0.13 sec. 0.13 sec.
ON
OFF DI±360
± DIAGNOSTICSANTI±LOCK BRAKE SYSTEM WITH EBD & RBS
2001 PRIUS (RM778U)
(g) In case of using TOYOTA hand±held tester:
Clear the DTC.
(1) Hook up the TOYOTA hand±held tester to the
DLC3.
(2) Turn the ignition switch ON.
(3) Operate the TOYOTA hand±held tester to erase the
codes.
HINT:
Please refer to the TOYOTA hand±held tester operator's manu-
al for further details.
3. SENSOR SIGNAL CHECK (TEST MODE)
HINT:
If the ignition switch is turned from ON to ACC or LOCK during
test mode, DTC will be erased.
(a) In case of not using TOYOTA hand±held tester:
Check the sensor signal.
(1) Turn the ignition switch OFF.
(2) Using SST, connect terminals Ts and CG of DLC3.
SST 09843±18040
(3) Start the engine.
(4) Check that the ABS warning light blinks.
HINT:
If the ABS warning light does not blink, inspect the ABS warning
light circuit and Ts terminal circuit (See page DI±437,
DI±449).
(5) Keep the vehicle in the stationary condition and the
brake pedal in free condition for 1 sec. or more.
(6) Keeping the vehicle in the stationary condition, de-
press the brake pedal with 98 N (10 kgf, 22 lbf) or
more for 1 sec. or more.
(7) Drive vehicle straight forward.
When driving the vehicle at the speed faster than 45
km/h (28 mph) for several seconds, check that the
ABS warning light comes off.
HINT:
There is a case that the sensor check is not completed if the ve-
hicle has its front wheels spun or its steering wheel steered dur-
ing this check.

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.