wheel bolts TOYOTA PRIUS 2001 Service Repair Manual

P21235
MA049±01
F12933
F12919
MA±8
± MAINTENANCEBODY
61 Author: Date:
2001 PRIUS (RM778U)
BODY
INSPECTION
1. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY
Tighten these parts:

Front seat mount bolts
Torque: 37 N´m (375 kgf´cm, 27 ft´lbf)

Front suspension member±to±body mounting bolts
Torque:
Bolt A: 113 N´m (1,150 kgf´cm, 83 ft´lbf)
Bolt B: 157 N´m (1,600 kgf´cm, 116 ft´lbf)

Rear suspension member±to±body mounting nuts
Torque: 90 N´m (918 kgf´cm, 66 ft´lbf)
2. FINAL INSPECTION
(a) Check the operation of the body parts:

Hood:
Auxiliary catch operate properly
Hood locks securely when closed

Front and rear doors:
Door lock operates properly
Doors close properly

Luggage compartment door:
Door lock operates properly

Seats:
Seat adjusts easily and locks securely in any posi-
tion
Front seat back locks securely in any position
Folding±down rear seat backs lock securely
(b) Road test:

Check the engine and chassis for abnormal noises.

Check that the vehicle does not wander or pull to
one side.

Check that the brake work properly and do not drag.
(c) Be sure to deliver a clean car. especially check:

Steering wheel

Shift lever knob

All switch knobs

Door handles

Seats

A13915
A13916
A13917
SST
SST
A13918
SST SST
EM±56
± ENGINE MECHANICALENGINE UNIT
2001 PRIUS (RM778U)
(b) Remove the nut and disconnect the LH engine mounting
from the insulator.
31. REMOVE ENGINE AND TRANSAXLE ASSEMBLY
(a) Lower the engine out of vehicle slowly and carefully.
NOTICE:
Make sure the engine is clear of all wiring, hoses and
cables.
(b) Using a engine sliding device, and place the engine and
transaxle assembly onto the stand.
32. SEPARATE ENGINE AND TRANSAXLE
(a) Remove the 2 bolts and dust cover.
(b) Remove the 6 bolts and transaxle from the engine.
33. REMOVE DAMPER DISC
Using SST, hold the crankshaft pulley, remove the 6 bolts and
damper disc and spring.
SST 09213±58012 (91111±580845), 09330±00021
34. REMOVE FLYWHEEL
Using SST, hold the crankshaft pulley, remove the 6 bolts and
flywheel.
SST 09213±58012 (91111±580845), 09330±00021

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)

F11573
Front:
Rear:SA1CK±11
Z03382
Alignment
TesterGauge
F07339
SA±4
± SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
1454 Author: Date:
2001 PRIUS (RM778U)
FRONT WHEEL ALIGNMENT
INSPECTION
1. MEASURE VEHICLE HEIGHT
Vehicle height:
Tire sizeFront*1 mm (in.)Rear*2 mm (in.)
175/65R14191 (7.52)239 (9.41)
*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.
NOTICE:
Before inspecting the wheel alignment, adjust the vehicle
height to the specified value.
If the vehicle height is not the specified value, try to adjust it by
pushing down on or lifting the body.
2. INSTALL CAMBER±CASTER±KINGPIN GAUGE OR
POSITION VEHICLE ON WHEEL ALIGNMENT TES-
TER
Follow the specific instructions of the equipment manufacturer.
3. INSPECT CAMBER, CASTER AND STEERING AXIS
INCLINATION
Camber, caster and steering axis inclination:
Camber
Right±left error±0°26' ± 45' (±0.43° ± 0.75°)
45' (0.75°) or less
Caster
Right±left error1°02' ± 45' (1.03° ± 0.75°)
45' (0.75°) or less
Steering axis inclination
Right±left error9°52' ± 45' (9.87° ± 0.75°)
45' (0.75°) or less
If the caster and steering axis inclination are not within the spe-
cified values, after the camber has been correctly adjusted, re-
check the suspension parts for damaged and/or worn out parts.
4. ADJUST CAMBER
NOTICE:
After the camber has been adjusted, inspect the toe±in.
(a) Remove the front wheel.
(b) Remove the 2 nuts on the lower side of the shock absorb-
er.
If reusing the bolts and/or nuts, coat the threads of nuts with en-
gine oil.
(c) Clean the installation surfaces of the shock absorber and
the steering knuckle.
(d) Temporarily install the 2 nuts.

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.

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)

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.

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

BR1JL±01
F12503
F08657
SST
SST
BoltBolt
F12076
BR±56
± BRAKEREAR SPEED SENSOR
2001 PRIUS (RM778U)
REMOVAL
1. REMOVE REAR WHEEL
2. DISCONNECT SPEED SENSOR CONNECTOR
Disconnect the connector from the speed sensor.
3. REMOVE SPEED SENSOR WITH REAR AXLE HUB
(See page SA±46)
4. REMOVE SPEED SENSOR
(a) Using a pin punch and hammer, drive out the 2 pins and
remove the 2 attachments from SST.
SST 09520±00031
(b) Mount the rear axle hub in a soft jaw vise.
NOTICE:
Replace the axle hub assembly if it is dropped or a strong
shock is given to it.
(c) Using SST and 2 bolts (Diameter: 12 mm, Pitch: 1.5 mm),
remove the speed sensor.
SST 09520±00031 (09520±00040, 09521±00020),
09950±00020
NOTICE:

If a damage is inflicted to the sensor rotor, replace the
axle hub assembly.

Do not scratch the contacting surface of axle hub and
speed sensor.
5. IF NECESSARY, REPLACE SPEED SENSOR WIRE
HARNESS
(a) Remove the seat cushion, seatback and quarter trim
(See page BO±83).
(b) Disconnect the speed sensor wire harness connector.

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).