power steering TOYOTA PRIUS 2001 Service Manual PDF

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)

RS0JO±06
± SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
RS±1
1600 Author: Date:
2001 PRIUS (RM778U)
SRS AIRBAG
PRECAUTION
CAUTION:

The PRIUS is equipped with SRS, which comprises a driver airbag, front passenger airbag and
side airbag. Failure to carry out service operations in the correct sequence could cause the SRS
to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a
mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when re-
quired. Before performing servicing (including removal or installation of parts, inspection or
replacement), be sure to read the following items carefully, then follow the correct procedures
described in the repair manual.

Work must be started 90 seconds after the ignition switch is turned to the ºLOCKº position and
the negative (±) terminal cable is disconnected from the battery.
(The SRS is equipped with a back±up power source so that if work is started within 90 seconds
from disconnecting the negative (±) terminal cable of the battery, the SRS may be deployed.)

Do not expose the steering wheel pad, front passenger airbag assembly, side airbag assembly,
airbag sensor assembly, front airbag sensor or side airbag sensor assembly directly to hot air
or flames.
NOTICE:

Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most impor-
tant source of information when troubleshooting. When troubleshooting the SRS, always in-
spect the DTCs before disconnecting the battery.

Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front
passenger airbag assembly, side airbag assembly, airbag sensor assembly, front airbag sen-
sor and side airbag sensor assembly should be inspected.
(See page RS±14, RS±28, RS±41, RS±53, RS±58 and RS±63)

Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.

Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.

Never disassemble and repair the steering wheel pad, front passenger airbag assembly, side
airbag assembly, airbag sensor assembly, front airbag sensor or side airbag sensor assembly
in order to reuse it.

If the steering wheel pad, front passenger airbag assembly, side airbag assembly, airbag sen-
sor assembly, front airbag sensor or side airbag sensor assembly has been dropped, or if there
are cracks, dents or other defects in the case, bracket or connector, replace it with new one.

Use a volt/ohmmeter with high impedance (10 kW/V minimum) for troubleshooting the system's
electrical circuits.

Information labels are attached to the periphery of the SRS components. Follow the instruc-
tions on the notices.

After work on the SRS is completed, perform the SRS warning light check (See page DI±497).

When the negative (±) terminal cable is disconnected from the battery, the memory of the clock
and audio system will be canceled. So before starting work, make a record of the contents mem-
orized in the audio memory system. When work is finished, reset the audio systems as they
were before and adjust the clock. To avoid erasing the memory in each memory system, never
use a back± up power supply from outside the vehicle.

If the vehicle is equipped with a mobile communication system, refer to the precaution in the
IN section.

Z14034
Fig.1
Fig.2Power Source
Safing
Sensor
Squibs
Deceleration Sensor
H01581
Outer
H01582
Lock of connector is released
Disconnection is completed
± SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
RS±7
2001 PRIUS (RM778U)
(b) When the vehicle is involved in a frontal collision in the
hatched area (Fig. 1) and the shock is larger than the pre-
determined level, the SRS is activated automatically. A
safing sensor is designed to go on at a smaller decelera-
tion rate than the airbag sensor. As illustrated in Fig. 2,
ignition is caused when current flows to the squib, which
happens when a safing sensor and the deceleration sen-
sor go on simultaneously. When a deceleration force acts
on the sensors, 2 squibs in the driver airbag and front pas-
senger airbag ignite and generate gas. The gas discharg-
ing into the driver airbag and front passenger airbag rap-
idly increases the pressure inside the bags, breaking
open the steering wheel pad and instrument panel.
Bag inflation then ends, and the bags deflate as the gas
is discharged through discharge holes at the bag's rear or
side.
11. DISCONNECTION OF CONNECTORS FOR FRONT
AIRBAG SENSOR AND SIDE AIRBAG SENSOR
(a) While holding both flank sides of the outer, slide the outer
to the direction shown by an arrow.
(b) Lock of the connectors is released, then disconnect the
connectors.
HINT:
Be sure to hold both flank sides of the outer. If holding the top
and bottom sides, it will obstruct disconnection.

RS0R3±02
AB0152
SST
AB0158
SSTBattery RS±16
± SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
2001 PRIUS (RM778U)
DISPOSAL
HINT:
When scrapping vehicle equipped with an SRS or disposing of
a steering wheel pad (with airbag), always first deploy the air-
bag in accordance with the procedure described below. If any
abnormality occurs with the airbag deployment, contact the
SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC.
CAUTION:

Never dispose of a steering wheel pad which has an
undeployed airbag.

The airbag produces a sizeable exploding sound
when it deploys, so perform the operation out±of±
doors and where it will not create a nuisance to
nearby residents.

When deploying the airbag, always use the specified
SST (SRS Airbag Deployment Tool). Perform the op-
eration in a place away from electrical noise.
SST 09082±00700

When deploying an airbag, perform the operation at
least 10 m (33 ft) away from the steering wheel pad.

The steering wheel pad is very hot when the airbag is
deployed, so leave it alone for at least 30 minutes af-
ter deployment.

Use gloves and safety glasses when handling a steer-
ing wheel pad with the deployed airbag.

Always wash your hands with water after completing
the operation.

Do not apply water, etc. to a steering wheel pad with
the deployed airbag.
1. AIRBAG DEPLOYMENT WHEN SCRAPPING VE-
HICLE
HINT:
Have a battery ready as the power source to deploy the airbag.

R13455
10 m (33 ft) or more
SSTBattery
R06753
RS±18
± SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
2001 PRIUS (RM778U)
(4) Move the SST at least 10 m (33 ft) away from the
front of the vehicle.
(5) Close all the doors and windows of the vehicle.
NOTICE:
Take care not to damage the SST wire harness.
(6) Connect the SST red clip to the battery positive (+)
terminal and the black clip to the negative (±) termi-
nal.
(c) Deploy the airbag.
(1) Check that no one is inside the vehicle or within 10
m (33 ft) area around the vehicle.
(2) Press the SST activation switch and deploy the air-
bag.
CAUTION:

The steering wheel pad is very hot when the airbag is
deployed, so leave it alone for at least 30 minutes af-
ter deployment.

Use gloves and safety glasses when handling a steer-
ing wheel pad with the deployed airbag.

Always wash your hands with water after completing
the operation.

Do not apply water, etc. to a steering wheel pad with
the deployed airbag.

When scrapping a vehicle, deploy the airbag and
scrap the vehicle with the steering wheel pad still
installed.

When moving a vehicle for scrapping which has a
steering wheel pad with deployed airbag, use gloves
and safety glasses.
HINT:
The airbag deploys simultaneously as the LED of the SST ac-
tivation switch lights up.
2. DEPLOYMENT WHEN DISPOSING OF STEERING
WHEEL PAD ONLY
NOTICE:

When disposing of the steering wheel pad (with air-
bag) only, never use the customers vehicle to deploy
the airbag.

Be sure to follow the procedure given below when de-
ploying the airbag.
HINT:
Have a battery ready as the power source to deploy the airbag.