wheel torque TOYOTA PRIUS 2001 Service Owner's Manual

EM1J2±02
P08755
A13917
SSTSST
1
2
3
4
6
5
A13940
SST
A13917
SSTSST
1
2
3
4
6
5
EM±58
± ENGINE MECHANICALENGINE UNIT
2001 PRIUS (RM778U)
INSTALLATION
1. INSTALL FLYWHEEL
(a) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No. 08833±00070, THREE BOND 1324
or equivalent
(b) Install and uniformly tighten the new 6 bolts in several
passes, in the sequence shown.
Torque: 84 N´m (857 kgf´cm, 62 ft´lbf)
(c) Retighten the flywheel bolts by 90° in the numerical order
shown.
2. INSTALL DAMPER DISC
(a) Insert SST in the damper disc, then insert them in the fly-
wheel.
SST 09301±00110
HINT:
Take care not to insert damper disc in the wrong direction.
(b) Set the damper spring on the damper disc.
(c) Following the procedures shown in the illustration, tighten
the 6 bolts in the order starting the bolt locating near the
knock pin on the top.
Torque: 16 N´m (163 kgf´cm, 12 ft´lbf)
HINT:

Following the order in the illustration, tighten the bolts at
a time evenly.

Move SST up and down, right and left lightly, after check-
ing that the disc in the center, tighten the bolts.
3. INSTALL TRANSAXLE TO ENGINE
(a) Attach the transaxle to the engine, and install the 6 bolts.
Torque: 33 N´m (337 kgf´cm, 24 ft´lbf)
(b) Install the dust cover.
(c) Install the LH engine mounting bracket.
Torque: 52 N´m (530 kgf´cm, 38 ft´lbf)

F07326


1
2
: Use with adjusting bolt
F12938
Bolt
Adjusting
ValueSet BoltAdjusting Bolt90105±15001 90105±15004 90105±15005 90105±15006
121212121 Dot
2 Dots3 Dots
±1°30' ± ±1°15'
±1°15' ± ±1°00'
±1°00' ± ±45'
±45' ± ±30'
±30' ± ±15'
0' ± 15'
15' ± 30'
30' ± 45'
45' ± 1°00'
1°00' ± 1°15' ±15' ± 0'
1°15' ± 1°30'
± SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
SA±5
1455 Author: Date:
2001 PRIUS (RM778U)
(e) Adjust the camber by pushing or pulling the lower side of
the shock absorber in the direction in which the camber
adjustment is required.
(f) Tighten the nuts.
Torque: 153 N´m (1,560 kgf´cm, 113 ft´lbf)
(g) Install the front wheel.
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
(h) Check the camber.
HINT:

Try to adjust the camber to the center of the specified val-
ue.

Adjusting value for the set bolts is 6' ± 30' (0.1° ± 0.5°).
If the camber is not within the specified value, using the follow-
ing table, estimate how much additional camber adjustment will
be required, and select the camber adjusting bolt.
NOTICE:
Tighten the adjusting bolt with a washer and a new nut.
(i) Do the steps mentioned above again. At step (b), replace
1 or 2 selected bolts.
HINT:
When replacing the 2 bolts, replace 1 bolt for each time.

SA3213
Front A
DB
C
F11574
F11575
SA0028
Front AB
A B
A: Inside
B: Outside SA±6
± SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
1456 Author: Date:
2001 PRIUS (RM778U)
5. INSPECT TOE±IN
Toe±in:
Toe±in
(total)A + B: 0°06' ± 12' (0.1° ± 0.2°)
C ± D: 1 ± 2 mm (0.04 ± 0.08 in.)
If the toe±in is not within the specified value, adjust it at the rack
ends.
6. ADJUST TOE±IN
(a) Remove the rack boot set clips.
(b) Loosen the tie rod end lock nuts.
(c) Turn the right and left rack ends by an equal amount to
adjust the toe±in.
HINT:
Try to adjust the toe±in to the center of the specified value.
(d) Make sure that the lengths of the right and left rack ends
are the same.
Rack end length difference: 1.5 mm (0.059 in.) or less
(e) Torque the tie rod end lock nuts.
Torque: 74 N´m (750 kgf´cm, 55 ft´lbf)
(f) Place the boots on the seats and install the clips.
HINT:
Make sure that the boots are not twisted.
7. INSPECT WHEEL ANGLE
Turn the steering wheel fully and measure the turning angle.
Wheel turning angle:
Inside wheel42°42' ± 2°
(42.70° ± 2°)
Outside wheel: Reference35°54' (35.90°)
If the right and left inside wheel angles differ from the specified
value, check the right and left rack end lengths.

SA1ZR±01
F08617
R14731
Backlash:Deviation:
F12940SST
± SUSPENSION AND AXLEFRONT AXLE HUB
SA±9
2001 PRIUS (RM778U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. CHECK BEARING BACKLASH AND AXLE HUB DEVI-
ATION
(a) Remove the 2 bolts, brake caliper and disc.
(b) Support the brake caliper securely.
(c) Using a dial indicator, check the backlash near the center
of the axle hub.
Maximum: 0.05 mm (0.0020 in.)
If the backlash exceeds the maximum, replace the bearing.
(d) Using a dial indicator, check the deviation at the surface
of the axle hub outside the hub bolt.
Maximum: 0.07 mm (0.0028 in.)
If the deviation exceeds the maximum, replace the axle hub.
(e) Install the disc, 2 bolts and brake caliper.
Torque: 107 N´m (1,090 kgf´cm, 79 ft´lbf)
3. REMOVE DRIVE SHAFT LOCK NUT
(a) Using SST and a hammer, unstake the staked part of the
lock nut.
SST 09930±00010
(b) While applying the brakes, remove the nut.
Torque: 216 N´m (2,200 kgf´cm, 159 ft´lbf)
(c) Remove the brake caliper and disc.
(d) Support the brake caliper securely.
4. REMOVE ABS SPEED SENSOR
Torque: 8.0 N´m (82 kgf´cm, 71 in.´lbf)

SA20B±01
FA1535
SST
F12940SST
F11576
SST
± SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA±17
2001 PRIUS (RM778U)
REMOVAL
NOTICE:

The hub bearing could be damaged if it is subjected
to the vehicle weight, such as when moving the ve-
hicle with the drive shaft removed.
Therefore, if it is absolutely necessary to place the ve-
hicle weight on the hub bearing, first support it with
the SST.
SST 09608±16042 (09608±02021, 09608±02041)

After disconnecting the drive shaft from the axle hub,
work carefully so as not to damage the ABS speed
sensor rotor serrations on the drive shaft.
1. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. REMOVE ENGINE UNDER COVER
3. DRAIN ATF
4. REMOVE DRIVE SHAFT LOCK NUT
(a) Using SST and a hammer, unstake the staked part of the
lock nut.
SST 09930±00010
(b) While applying the brakes, remove the nut.
Torque: 216 N´m (2,200 kgf´cm, 159 ft´lbf)
5. DISCONNECT TIE ROD END FROM STEERING
KNUCKLE
(a) Remove the cotter pin and nut.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
HINT:
At the time of installation, if the holes for a new cotter pin are not
aligned, tighten the nut further up to 60°.
(b) Using SST, disconnect the tie rod end from the steering
knuckle.
SST 09628±62011

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.

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)

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).

BR1JA±01
F12629
Front Door Scuff Plate Cowl Side TrimHood Lock Release
Lever Lower Column CoverRadio Tuner Opening CoverCluster Finish Panel
Assembly Hazard Warning Switch
Lower Center Cluster
Finish PanelGlove Compartment
Door Finish PanelInstrument PanelNo. 3 Register No. 2 Side Defroster
Nozzle
Front Pillar GarnishPassenger Air Bag
Assembly Cluster Finish Panel
Combination Meter
Lower Finish PanelSteering Wheel Pad Steering Wheel
Spiral CableUpper Column Cover
Front Door Scuff PlateCowl Side Trim No. 1 RegisterNo. 1 Side Defroster
NozzleFront Pillar Garnish
: Specified torqueN´m (kgf´cm, ft´lbf)
50 (510, 37)
BR±10
± BRAKEPARKING BRAKE PEDAL
2001 PRIUS (RM778U)
COMPONENTS

F12060
± BRAKEFRONT BRAKE PAD
BR±25
2001 PRIUS (RM778U)
9. INSTALL CALIPER
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in the piston with a hammer handle or similar imple-
ment.
HINT:

Tape the hammer handle before use.

If the piston is difficult to push in, loosen the bleeder plug
and push in the piston while letting some brake fluid es-
cape.
(c) Install the caliper.
(d) Hold the sliding pin and torque the installation bolts.
Torque: 34 N´m (350 kgf´cm, 25 ft´lbf)
10. INSTALL FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
11. DEPRESS BRAKE PEDAL SEVERAL TIMES
12. CHECK THAT FLUID LEVEL IS AT MAX LINE