2001 TOYOTA PRIUS Service Repair Manual

BR±6
± BRAKEBRAKE FLUID
1521 Author: Date:
2001 PRIUS (RM778U)
HINT:
Do not keep the solenoid activated for 2 seconds, or more. Al-
low an interval of 20 seconds, or more if activating it continuous-
ly.
(r) Turn the SRRR solenoid OFF with the TOYOTA hand±
held tester, and release the brake pedal.
(s) Check that the pump motor stops after 20 seconds.
(t) Repeat step (q) to (s) 3 times.
(u) Turn the ignition switch OFF, and disconnect the TOYOTA
hand±held tester from DLC3.
(v) Clear the DTC (See page DI±353).
HINT:

Diagnosis codes are erased with the shift lever in P range.

After erasing, turn the ignition switch OFF to protect ECU.
4. CHECK FLUID LEVEL IN RESERVOIR
(a) With the ignition switch OFF, depress the brake pedal
more than 40 times.
(b) Remove the reservoir cap. Add brake fluid up to the
ºMAXº line.
Fluid: SAE J1703 or FMVSS NO. 116 DOT3

BR1JA±01
F12629
Front Door Scuff Plate Cowl Side TrimHood Lock Release
Lever Lower Column CoverRadio Tuner Opening CoverCluster Finish Panel
Assembly Hazard Warning Switch
Lower Center Cluster
Finish PanelGlove Compartment
Door Finish PanelInstrument PanelNo. 3 Register No. 2 Side Defroster
Nozzle
Front Pillar GarnishPassenger Air Bag
Assembly Cluster Finish Panel
Combination Meter
Lower Finish PanelSteering Wheel Pad Steering Wheel
Spiral CableUpper Column Cover
Front Door Scuff PlateCowl Side Trim No. 1 RegisterNo. 1 Side Defroster
NozzleFront Pillar Garnish
: Specified torqueN´m (kgf´cm, ft´lbf)
50 (510, 37)
BR±10
± BRAKEPARKING BRAKE PEDAL
2001 PRIUS (RM778U)
COMPONENTS

F12632
Parking Brake Wire
Lock NutAdjusting Nut
Return Spring
Pedal AssemblyPedal Bracket
Pedal PadCushion Plate
Parking Brake switch
5.4 (55, 48 in.´lbf)
Lithium soap base glycol grease: Specified torque
N´m (kgf´cm, ft´lbf)

Non±reusable part
Bushing

Bushing Clip
14 (143, 10)
Parking Brake Pedal Assembly
Nut
32 (327, 24)
13 (130, 9)
± BRAKEPARKING BRAKE PEDAL
BR±11
2001 PRIUS (RM778U)

BR1JF±01
F12415
Wiper Arm
Cowl Top Ven-
tilator Louver
LH
Hood to Cowl Top Seal
Wiper Motor & Link Assembly
Outer Front Cowl Top Panel
Converter and Inverter
Assembly
Front Door Scuff PlateLower Finish Panel Cowl Top Ventilator Louver RH
Finish Panel Engine Room
R/B No. 2

Gasket Clip
Cowl Side Trim
13 (130, 9)
Clevis PinWave Washer
Clip
Return Spring
Circuit Breaker
SensorMG 2
MG 1
20 (204, 15)
8.0 (82, 71 in.´lbf)
Clip
Lithium soap base glycol grease: Specified torque
N´m (kgf´cm, ft´lbf)

Non±reusable part
Reservoir Hose
Master Cylinder Reservoir Hose
8.0 (82, 71 in.´lbf)
8.0 (82, 71 in.´lbf)
Inverter Terminal
Cover

Gasket
Hood Lock Release
Lever
Connector Cover
Wiper Motor Cover
21 (214, 15)
26 (270, 20)
7.4 (75, 64 in.´lbf)
5.4 (55, 48 in.´lbf)
15 (155, 11)
21 (214, 15)
BR±16
± BRAKEBRAKE MASTER CYLINDER
1531 Author: Date:
2001 PRIUS (RM778U)
BRAKE MASTER CYLINDER
COMPONENTS

F12630
Clevis Clevis Lock Nut
Cylinder Boot
No. 2 Piston
Lithium soap base glycol grease: Specified torque
N´m (kgf´cm, ft´lbf)
Master Cylinder Body

Non±reusable part
No. 1 Piston

Plug
Snap Ring
26 (265, 19)
± BRAKEBRAKE MASTER CYLINDER
BR±17
1532 Author: Date:
2001 PRIUS (RM778U)

F12057
BR1J3±01
F12058
BR±24
± BRAKEFRONT BRAKE PAD
2001 PRIUS (RM778U)
REPLACEMENT
1. REMOVE FRONT WHEEL
2. INSPECT PAD LINING THICKNESS
Check the pad thickness through the caliper inspection hole
and replace the pads if they are not within the specification.
Minimum thickness: 1.0mm (0.039 in.)
3. LIFT UP CALIPER
(a) Hold the sliding pin and remove the bottom side installa-
tion bolt.
HINT:
Do not disconnect the flexible hose from the brake caliper.
(b) Lift up the caliper and suspend it securely.
4. REMOVE 2 PADS WITH 4 ANTI±SQUEAL SHIMS
5. REMOVE 2 PAD SUPPORT PLATES
NOTICE:
The support plates can be used again provided that they
have sufficient rebound, no deformation, cracks or wear,
and have had all rust, dirt and foreign particles cleaned off.
6. CHECK DISC THICKNESS AND RUNOUT
(See page BR±29 )
7. INSTALL PAD SUPPORT PLATES
Install the 2 pad support plates.
NOTICE:
Do not assemble the upper and lower pad support plates
in reverse.
8. INSTALL NEW PADS
NOTICE:
When replacing worn pads, the anti±squeal shims must be
replaced together with the pads.
(a) Apply disc brake grease to both side of the inner anti±
squeal shim (See page BR±23).
(b) Install the 2 anti± squeal shims on each pad.
(c) Install the inner pad with the pad wear indicator plate fac-
ing upward.
(d) Install the outer pad.
NOTICE:
There should be no oil or grease adhering to the friction
surfaces of the pads or the disc.