suspension TOYOTA PRIUS 2001 Service Workshop Manual

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)

F11619
SA±52
± SUSPENSION AND AXLEREAR SHOCK ABSORBER
2001 PRIUS (RM778U)
(b) Remove the nut, washer and shock absorber.
Torque: 80 N´m (816 kgf´cm, 59 ft´lbf)

SA1ZV±01
F11600
F11601
SST
F11602
SST
F11603
SA±60
± SUSPENSION AND AXLEREAR AXLE BEAM
2001 PRIUS (RM778U)
REPLACEMENT
1. REMOVE TOE CONTROL LINK
(a) Remove the nut.
(b) Using a brass bar, remove the bolt.
(c) Using a SST, remove the toe control link from axle beam.
SST 09710±40010 (09711±40010, 09712±40010),
09727±30021 (09727±00010, 09727±00031)
NOTICE:

Make sure that the arm inside of SST is contact with
the toe control link at the position shown in the il-
lustration.

Never use SST (09727 ± 00030)
HINT:
The outer race of the toe control link is made of rubber and be-
cause of its elasticity, it is difficult to remove the link from the axle
beam.
So, tap the part indicated by the arrow with a plastic hammer
when removing.
2. INSTALL TOE CONTROL LINK
(a) Using a SST, install a new toe control link.
SST 09710±40010 (09711±40010, 09712±40010),
09727±30021 (09727±00010, 09727±00031)
NOTICE:

Make sure that the arm inside of SST is contact with
the frange of the toe control link.

Align the bolt holes of the toe control link and axle
beam in the direction of press±fitting.
When the bolt holes slip off the aligned position,
press±fit a new toe control link again.
HINT:

Until the outer race is fit into the axle beam, adjust the arm
position of SST to set the toe control link upright to the
axle beam.

When the toe control link is fully press±fit into the axle
beam, the bolt holes are not aligned.

F11604
± SUSPENSION AND AXLEREAR AXLE BEAM
SA±61
2001 PRIUS (RM778U)
(b) Using a extension bar and press, install a new bolt.
NOTICE:
Press in the bolt until the base of the bolt head is pressed
tightly against the axle beam.
(c) Install the a nut.

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

SR1BL±01
F12196
F12214
A
B
± STEERINGELECTRIC POWER STEERING GEAR
SR±19
2001 PRIUS (RM778U)
REMOVAL
NOTICE:
Remove the steering wheel assembly before the steering
gear removal, because there is possibility of breaking of
the spiral cable.
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. REMOVE STEERING WHEEL PAD (See page SR±6)
3. REMOVE STEERING WHEEL (See page SR±6)
4. REMOVE RH AND LH ENGINE UNDER COVERS
5. DISCONNECT RH AND LH TIE ROD ENDS (See page
SA±9)
6. DISCONNECT STABILIZER BAR (See page SA±41)
7. DISCONNECT LOWER SUSPENSION ARM FROM
LOWER BALL JOINT (See page SA±41)
8. DISCONNECT 2 CONNECTORS AND EMPS BRACK-
ET
(a) Disconnect the 2 connectors.
(b) Disconnect the 2 clamps.
(c) Remove the bolt and disconnect the earth wire.
(d) Remove the 2 bolts and EMPS bracket.
9. DISCONNECT NO. 2 INTERMEDIATE SHAFT AS-
SEMBLY
(a) Place the 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.
10. DISCONNECT TORQUE ROD (See page SA±41)
11. REMOVE SUSPENSION MEMBER AND ELECTRIC
POWER STEERING GEAR ASSEMBLY (See page
SA±41)
12. REMOVE ELECTRIC POWER STEERING GEAR AS-
SEMBLY
(a) Remove the stabilizer bar (See page SA±41).

F12197
SR±20
± STEERINGELECTRIC POWER STEERING GEAR
2001 PRIUS (RM778U)
(b) Remove the 4 bolts and electric power steering gear as-
sembly from the front suspension member.
(c) Remove the bracket and grommet from the electric power
steering gear assembly.

SR1BO±01
F12847
Front
F12197
F15034
Serrated Part
F15035
Main Shaft Lower
Dust Seal
Body
Engine Compartment SideCab Side
± STEERINGELECTRIC POWER STEERING GEAR
SR±25
2001 PRIUS (RM778U)
INSTALLATION
1. INSTALL ELECTRIC POWER STEERING GEAR AS-
SEMBLY
(a) Install the grommet and bracket to the electric power
steering gear assembly.
HINT:
Install the bracket with the inscribed mark facing to the front of
the vehicle.
(b) Install the electric power steering gear assembly with the
4 new bolts to the front suspension member.
Torque: 83 N´m (850 kgf´cm, 61 ft´lbf)
(c) Install the stabilizer bar (See page SA±43).
(d) To prevent the main shaft lower dust seal from damaging,
wind vinyl tape on the serrated part of the control valve
shaft.
(e) Turn over the main shaft lower dust seal from the engine
compartment side to the cab.
2. INSTALL SUSPENSION MEMBER AND ELECTRIC
POWER STEERING GEAR ASSEMBLY (See page
SA±43)
3. CONNECT TORQUE ROD (See page SA±43)

F12196
F12214
Matchmarks
A
B
SR±26
± STEERINGELECTRIC POWER STEERING GEAR
2001 PRIUS (RM778U)
4. CONNECT EMPS BRACKET AND 2 CONNECTORS
(a) Connect the EMPS bracket with the 2 bolts.
Torque: 5.5 N´m (60 kgf´cm, 52 in.´lbf)
(b) Connect the earth wire with the bolt.
Torque: 5.5 N´m (60 kgf´cm, 52 in.´lbf)
(c) Connect the 2 clamps.
(d) Connect the 2 connectors.
5. CONNECT LOWER SUSPENSION ARM TO LOWER
BALL JOINT (See page SA±43)
6. CONNECT STABILIZER BAR (See page SA±43)
7. CONNECT NO. 2 INTERMEDIATE SHAFT ASSEMBLY
(a) Put the dust seal back to the engine compartment side.
(b) Remove the vinyl tape from the serrated part of the control
valve shaft.
(c) Align the matchmarks on the No. 2 intermediate shaft as-
sembly and control valve shaft.
(d) Install the bolt ºBº and torque the bolt ºAº.
Torque: 35 N´m (360 kgf´cm, 22 ft´lbf)
8. CONNECT RH AND LH TIE ROD ENDS
(See page SA±14)
9. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
HINT:
Do it with the front of the vehicle jacked up.
10. CENTER SPIRAL CABLE (See page SR±14)
11. INSTALL STEERING WHEEL
(a) Align the matchmarks on the steering wheel and steering
column main shaft.
(b) Temporarily tighten the steering wheel set nut.
12. CHECK STEERING WHEEL CENTER POINT
13. TORQUE STEERING WHEEL SET NUT
Torque: 50 N´m (510 kgf´cm, 37 ft´lbf)
14. INSTALL STEERING WHEEL PAD (See page SR±14)
15. CHECK FRONT WHEEL ALIGNMENT
16. PERFORM CALIBRATION OF TORQUE SENSOR
ZERO POINT (See page DI±454)