TOYOTA PRIUS 2001 Service Repair Manual

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.

SS04X±12
± SERVICE SPECIFICATIONSSUSPENSION AND AXLE
SS±27
2001 PRIUS (RM778U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
FRONT AXLE
Hub nut1031,05076
Tie rod end lock nut7475055
Steering knuckle x Shock absorber1531,56011 3
Steering knuckle x Brake caliper1071,09079
Steering knuckle x Tie rod end4950036
Axle hub x Drive shaft2162,200159
Lower ball joint x Lower suspension arm1421,450105
Lower ball joint x Steering knuckle1031,05076
Steering knuckle x Dust cover8.38574 in.´lbf
ABS speed sensor set bolt8.08271 in.´lbf
FRONT SUSPENSION
Suspension support x Body3940029
Suspension support x Piston rod4747534
Flexible hose x Shock absorber2930022
ABS speed sensor wire harness x Shock absorber5.45548 in.´lbf
Lower suspension arm set bolt1371,397101
Suspension member set bolt Front side
Rear side11 3
1571,152
1,60083
11 6
Torque rod x Suspension member1001,03074
Stabilizer bar bracket x Suspension member1919414
Stabilizer bar link set nut7475555
REAR AXLE
Hub nut1031,05076
Axle hub set bolt5252538
REAR SUSPENSION
Shock absorber x Axle Beam8081659
ABS speed sensor wire harness x Axle Beam5.45548 in.´lbf
Spring bracket x Body8081659
Shock absorber center nut5657141
Parking brake cable set bolt5.45548 in.´lbf
Toe control link x Body9091866
Toe control link x Axle beam9091866
Stabilizer bar set bolt1491,51911 0

SS0LM±06
SS±28
± SERVICE SPECIFICATIONSBRAKE
150 Author: Date:
2001 PRIUS (RM778U)
BRAKE
SERVICE DATA
BRAKE PEDAL
Brake pedal height from asphalt sheet127 ± 137 mm (5.08 ± 5.48 in.)
Brake pedal freeplay1 ± 6 mm (0.04 ± 0.24 in.)
Brake pedal reserve distance at 200 N (20 kgf, 45 Ibf)More than 85 mm (3.35 in.)
PARKING BRAKE PEDAL
Parking brake pedal travel at 294N (30 Kgf, 66.1 Ibf)5 ± 8 clicks
FRONT BRAKE
Front brake pad thickness STD11.0 mm (0.433 in.)
Front brake pad thickness Minimum1.0 mm (0.039 in.)
Front brake disc thickness STD22.0 mm (0.984 in.)
Front brake disc thickness Minimum20.0 mm (0.906 in.)
Front brake disc runout Maximum0.05 mm (0.0020 in.)
REAR BRAKE
Drum brake shoe lining thickness STD4.0 mm (0.157 in.)
Drum brake shoe lining thickness Minimum1.0 mm (0.039 in.)
Rear brake drum inside diameter STD200.0 mm (7.874 in.)
Rear brake drum inside diameterMaximum201.0 mm (7.913 in.)
Rear brake drum to shoe clearance0.6 mm (0.024 in.)

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

SS02V±05
± SERVICE SPECIFICATIONSBODY ELECTRICAL
SS±33
155 Author: Date:
2001 PRIUS (RM778U)
BODY ELECTRICAL
SERVICE DATA
DAYTIME RUNNING RELAY (MAIN) (Wire harness side)
12 ± Ground (Ignition switch OFF)No voltage
12 ± Ground (Ignition switch ON)Battery voltage
9 ± Ground (Engine Running)Battery voltage
3 ± Ground (Constant)Battery voltage
6 ± Ground (Constant)Battery voltage
SPEEDOMETER (ON±VEHICLE)
Standard indication (mph)Allowable range (mph)
2018 ± 22
4038 ± 42
6059 ± 63
8079 ± 83
10099 ± 104
120119 ± 125
Standard indication (km/h)Allowable range (km/h)
2018 ± 22
4038 ± 42
6058 ± 62
8078 ± 82
10097 ± 103
120117 ± 123
140137 ± 143
160157 ± 163
FUEL SENDER GAUGE
Float position mm (in.)Resistance (W)
F: Approx. 25.2 (0.99)Approx. 430
1/2: Approx. 92.6 (3.65)Approx. 1000 ± 2000
E: Approx. 169 (6.65)Approx. 5000
DEFOGER SWITCH (Wire harness side)
1 ± Ground (Ignition switch LOCK or ACC)No voltage
1 ± Ground (Ignition switch ON)Battery voltage
8 ± Ground (Constant)Battery voltage
WIRELESSS DOOR LOCK CONTROL RECEIVER (Wire harness side)
5 ± Ground (Constant)Battery voltage
POWER MIRROR SWITCH (Wire harness side)
8 ± Ground (Ignition switch LOCK)No voltage
8 ± Ground (Ignition switch ACC or ON)Battery voltage
RADIO RECEIVER (Wire harness side)
3 ± Ground (Ignition switch LOCK)No voltage
3 ± Ground (Ignition switch ACC or ON)Battery voltage
4 ± Ground (Constant)Battery voltage
CENTER CLUSTER SWITCH (Wire harness side)
1 ± Ground (Ignition switch ACC or ON)Battery voltage

SS±34
± SERVICE SPECIFICATIONSBODY ELECTRICAL
156 Author: Date:
2001 PRIUS (RM778U) 1 ± Ground (Ignition switch LOCK)
No voltage
2 ± Ground (Constant)Battery voltage
TRANSPONDER KEY ECU (Wire harness side)
1 ± Ground (Constant)Battery voltage
2 ± Ground (Ignition switch ON)Battery voltage

SS1HM±01
± SERVICE SPECIFICATIONSBODY
SS±35
157 Author: Date:
2001 PRIUS (RM778U)
BODY
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
FRONT BUMPER±±±
Side marker x Bumper1.71715 in.´lbf
HOOD±±±
Hood x Hinge131309
Hood lock x Body8.38574 in.´lbf
FRONT DOOR±±±
Outside view mirror x Door7.88069 in.´lbf
Window regulator arm x Door4.95043 in.´lbf
Window regulator body x Door8.38574 in.´lbf
Door lock x Door Bolt:4.95043 in.´lbf
Door lock x Door Screw:4.95043 in.´lbf
Outside handle x Door5.45548 in.´lbf
Hinge x Body4344032 in.´lbf
Hinge x Door4344032 in.´lbf
Door lock striker x Body2323017 in.´lbf
REAR DOOR±±±
Window regulator x Door5.45548 in.´lbf
Door lock x Door4.95043 in.´lbf
Outside handle x Body5.45548 in.´lbf
Hinge x Body2526019
Hinge x Door3031022
Door lock striker x Body2323017
LUGGAGE COMPARTMENT DOOR AND HINGE±±±
Door lock x Door5.45548 in.´lbf
Hinge x Door8.38574 in.´lbf
Door lock striker x Body5.45548 in.´lbf
FRONT WIPER AND WASHER±±±
Wiper arm x Wiper link2627020
Wiper motor x Wiper link Bolt:5.45548 in.´lbf
Wiper motor x Wiper link Nut:1717513
Wiper link x Outer front cowl top panel7.47565 in.´lbf
Outer front cowl top panel x Body5.45548 in.´lbf
ROOF HEADLINING±±±
Inner rear view mirror x Body2.93026 in.´lbf
INSTRUMENT PANEL±±±
Front passenger airbag assembly x Reinforcement2020415
FRONT SEAT±±±
Seat cushion frame x Body3738027
Seatback assembly x Seat cushion frame4344032
REAR SEAT±±±
Seatback assembly x Body7.98170 in.´lbf

SS±36
± SERVICE SPECIFICATIONSBODY
158 Author: Date:
2001 PRIUS (RM778U) SEAT BELT
±±±
Outer belt shoulder anchor x Anchor adjuster4243031
Anchor adjuster x Body4243031
Seat belt floor anchor x Body4243031
Retractor x Body Upper bolt:4.95043 in.´lbf
Retractor x Body Lower bolt:4243031
Inner belt x Seat cushion frame4142030
Rear seat belt retractor x Body4243031
Rear seat inner belt x Body4243031
CRS Tether anchor bracket x Body2020014
CRS Anchor bracket sub±assembly x Body3132023
SPOILER±±±
Rear spoiler x Body5.05144 in.´lbf