power steering TOYOTA PRIUS 2001 Service Manual PDF

EM1J0±02
A13907
A13943
± ENGINE MECHANICALENGINE UNIT
EM±53
2001 PRIUS (RM778U)
REMOVAL
1. DISCONNECT BATTERY NEGATIVE (±) TERMINAL
AND HV BATTERY SERVICE PLUG
(See page HV±1)
2. REMOVE OUTER FRONT COWL TOP PANEL AS-
SEMBLY (See page BO±32)
3. DRAIN HV COOLANT (See page HT±8)
4. DRAIN ENGINE COOLANT
5. REMOVE CONVERTER AND INVERTER ASSEMBLY
(See page HV±18)
6. REMOVE HEATER UNIT WATER PUMP
(See page AC±55)
7. REMOVE AIR CLEANER ASSEMBLY
(a) Disconnect the MAF meter connector.
(b) Disconnect the EVAP hose from the air cleaner case.
(c) Loosen the 2 hose clamps.
(d) Remove the 2 bolts and air cleaner assembly.
8. DISCONNECT CONNECTORS, CLAMPS AND HOSES
(a) Disconnect the engine wire clamps.
(b) Disconnect the heated oxygen sensor connector.
(c) Disconnect the 2 power steering connectors.
(d) Disconnect the VSV connector for purge line.
(e) Disconnect the VSV hose for purge line.
(f) Disconnect the ground strap from RH fender apron.
(g) Disconnect the ground strap from LH fender apron.
9. REMOVE AIR INLET
10. REMOVE ENGINE COOLANT RESERVOIR TANK
11. DISCONNECT 2 RADIATOR HOSES FROM RADIATOR
12. DISCONNECT HEATER HOSE FROM CYLINDER
BLOCK

A13943
A13907
± ENGINE MECHANICALENGINE UNIT
EM±61
2001 PRIUS (RM778U)
25. CONNECT CONNECTORS, CLAMPS AND HOSES
(a) Connect the Ground strap from LH fender apron.
(b) Connect the Ground strap from RH fender apron.
(c) Connect the VSV hose for purge line.
(d) Connect the VSV connector for purge line.
(e) Connect the 2 power steering connectors.
(f) Connect the Heated oxygen sensor connector.
(g) Connect the Engine wire clamps.
26. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner assembly with the 2 bolts.
(b) Tighten the 2 hose clamps.
(c) Connect the EVAP hose to the air cleaner case.
(d) Connect the MAF meter connector.
27. INSTALL HEATER UNIT WATER PUMP
(See page AC±55)
28. INSTALL CONVERTER AND INVERTER ASSEMBLY
(See page HV±22)
29. INSTALL OUTER FR COWL TOP PANEL ASSEMBLY
(See page BO±35)
30. FILL WITH ENGINE COOLANT
31. FILL WITH HV COOLANT
32. INSTALL ENGINE UNDER COVERS
33. CONNECT BATTERY NEGATIVE (±) TERMINAL AND
HV BATTERY SERVICE PLUG (See page HV±1)
34. ROAD TEST VEHICLE
Check for abnormal noiss, shock slippage, correct shift points
and smooth operation.
35. RECHECK ENGINE COOLANT AND HV TRANSAXLE
COOLANT

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

F12262
Tie Rod End
Clip
Rack Boot
Clamp
Rack End
PS Gear Assembly
with Motor
Claw Washer


83 (850, 61)
* 62 (630, 46)
Claw Washer


Rack End83 (850, 61)
* 62 (630, 46)
Clamp
Rack Boot
Clip
Tie Rod End
Lock Nut56 (570, 41)
Lock Nut56 (570, 41)
N´m (kgf´cm, ft´lbf) : Specified torque
Non±reusable part
* For use with SST

5.5 (60, 52 in.´lbf)
Earth
Wire
SR±18
± STEERINGELECTRIC POWER STEERING GEAR
1591 Author: Date:
2001 PRIUS (RM778U)

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.

SR1BM±01
F12264
SST
F07501
Matchmarks
F12265
F12266
SST
± STEERINGELECTRIC POWER STEERING GEAR
SR±21
2001 PRIUS (RM778U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. SECURE ELECTRIC POWER STEERING GEAR AS-
SEMBLY IN VISE
Using SST, secure the electric power steering gear assembly
in a vise.
SST 09612 ± 00012
2. REMOVE RH AND LH TIE ROD ENDS AND LOCK
NUTS
(a) Place matchmarks on the tie rod end, lock nut and rock
end.
(b) Loosen the lock nut and remove the tie rod end and lock
nut.
(c) Employ the same manner described above to the other
side.
3. REMOVE RH AND LH CLAMPS, CLIPS AND RACK
BOOTS
(a) Remove the clamp, clip and rack boot.
NOTICE:
Be careful not to damage the boot.
HINT:
Mark the RH and LH rack boots.
(b) Employ the same manner described above to the other
side.
4. REMOVE RH AND LH RACK ENDS CLAW WASHERS
(a) Using a screwdriver and a hammer, unstake the washer.
NOTICE:
Avoid any impact on the steering rack.
(b) Using a spanner, hold the steering rack steadily and using
SST, remove the rack end.
SST 09922 ± 10010
NOTICE:
Use SST 09922 ± 10010 in the direction shown in the il-
lustration.
HINT:
Mark the RH and LH rack ends.
(c) Remove the claw washer.

SR±22
± STEERINGELECTRIC POWER STEERING GEAR
2001 PRIUS (RM778U)
(d) Employ the same manner described above to the other
side.
5. REMOVE EARTH WIRE
Remove the bolt and earth wire.

SR1BN±01
F12267
F12268
Fulcrum LengthSST
F12269
± STEERINGELECTRIC POWER STEERING GEAR
SR±23
2001 PRIUS (RM778U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. INSTALL EARTH WIRE
Install the earth wire with the bolt.
Torque: 5.5 N´m (60 kgf´cm, 52 in.´lbf)
2. INSTALL RH AND LH CLAW WASHERS AND RACK
ENDS
(a) Install a new claw washer and temporarily install the rack
end.
HINT:
Align the claws of the claw washer with the steering rack
grooves.
(b) Using a spanner, hold the steering rack steadily and using
SST, torque the rack end.
SST 09922 ± 10010
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
NOTICE:
Use SST 09922 ± 10010 in the direction shown in the il-
lustration.
HINT:
Use a torque wrench with a fulcrum length of 380 mm (14.96
in.).
(c) Using a brass bar and a hammer, stake the claw washer.
NOTICE:
Avoid any impact on the steering rack.
(d) Employ the same manner described above to the other
side.
3. INSTALL RH AND LH RACK BOOTS, CLIPS AND
CLAMPS
(a) Ensure that the steering rack hole is not clogged with
grease.
HINT:
If the hole is clogged, the pressure inside the boot will change
after it is assembled and the steering wheel is turned.
(b) Install the boot, clip and clamp.
NOTICE:
Be careful not to damage or twist the boot.

F07501
Matchmarks
SR±24
± STEERINGELECTRIC POWER STEERING GEAR
2001 PRIUS (RM778U)
(c) Employ the same manner described above to the other
side.
4. INSTALL RH AND LH TIE ROD ENDS AND LOCK NUT
(a) Screw the lock nut and tie rod end onto the rack end and
the matchmarks aligned.
(b) After adjusting toe±in. torque the nut (See page
SA±4).
(c) Employ the same manner described above to the other
side.