2001 TOYOTA PRIUS O2 sensor

HV00D±01
B11978
B11980
B12004
B11979
A
A
AB
B
B
B12005
HV±22
± HYBRID VEHICLE CONTROLCONVERTER AND INVERTER ASSEMBLY
2001 PRIUS (RM778U)
INSTALLATION
1. INSTALL CONVERTER & INVERTER ASSEMBLY
(a) Install the converter & inverter assembly with the 4 bolts.
Torque: 21 N´m (214 kgf´cm, 15 ft´lbf)
(b) Connect the 3 water hoses to the converter & inverter as-
sembly.
(c) Connect the 4 connectors.
(d) Connect the 2 power cable connectors.
(e) Install the ground cable to the radiator upper support.
Torque: 8.0 N´m (82 kgf´cm, 71 in.´lbf)
(f) Install the power cable for MG1 with the 3 bolts.
Torque: 7.0 N´m (71 kgf´cm, 62 in.´lbf)
NOTICE:
Be careful to prevent foreign matter from entering the in-
side of connector cover.
(g) Install the connector cover and circuit breaker sensor with
the2 screws.
Torque: 20 N´m (204 kgf´cm, 15 ft´lbf)
(h) Connect the connector for circuit breaker sensor.
(i) Install the 3 power cables for MG2 with the 6 bolts.
Torque:
Bolt A: 19.5 N´m (199 kgf´cm, 14 ft´lbf)
Bolt B: 8.0 N´m (82 kgf´cm, 71 in.´lbf)
NOTICE:
Be careful to prevent foreign matter from entering the in-
side of connector cover.
(j) Install the gasket and inverter terminal cover with the 4
screws.
Torque: 8.0 N´m (82 kgf´cm, 71 in.´lbf)
2. INSTALL COWL TOP PANEL (See page BO±31)
3. INSTALL SERVICE PLUG (See page HV±1)
4. FILL WITH HV COOLANT (See page HT±6)

HT00J±02
D09790
HT±54
± HYBRID TRANSAXLESHIFT LOCK SYSTEM
2001 PRIUS (RM778U)
INSPECTION
1. INSPECT SHIFT POSITION SENSOR
(a) Remove the steering column upper cover and lower cov-
er.
(b) Disconnect the shift position sensor connector.
(c) Check continuity between terminals shown below when
the shift lever is moved to each position
Shift PositionTerminal No. to continuityTerminal No. to continuity
P1 ± 23 ± 8 ± 9
R1 ± 43 ± 8 ± 9
N1 ± 53 ± 8 ± 9
D1 ± 63 ± 8 ± 9
B1 ± 73 ± 8 ± 9
(d) Connect the shift position sensor connector.
(e) Install the steering column upper cover and lower cover.

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)

F12941
F11576
SST
F11617
F12941
SA±10
± SUSPENSION AND AXLEFRONT AXLE HUB
2001 PRIUS (RM778U)
5. LOOSEN 2 NUTS ON LOWER SIDE OF SHOCK AB-
SORBER
Torque: 153 N´m (1,560 kgf´cm, 113 ft´lbf)
HINT:
Do not remove the 2 bolts and nuts.
6. DISCONNECT TIE ROD END FROM STEERING
KNUCKLE
(a) Remove the cotter pin and nut.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
HINT:
At the time of installation, if the holes for a new cotter pin are not
aligned, tighten the nut further up to 60°.
(b) Using SST, disconnect the tie rod end from the steering
knuckle.
SST 09628±62011
7. DISCONNECT LOWER SUSPENSION ARM FROM
LOWER BALL JOINT
Remove the 2 nuts and bolt.
Torque: 142 N´m (1,450 kgf´cm, 105 ft´lbf)
8. REMOVE STEERING KNUCKLE WITH AXLE HUB
(a) Remove the 2 bolts and nuts on the lower side of the
shock absorber.
HINT:
At the time of installation, coat the nut's thread with engine oil.
(b) Remove the steering knuckle with the axle hub.
NOTICE:
Be careful not to damage the boot and ABS speed sensor
rotor.

SA20B±01
FA1535
SST
F12940SST
F11576
SST
± SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA±17
2001 PRIUS (RM778U)
REMOVAL
NOTICE:

The hub bearing could be damaged if it is subjected
to the vehicle weight, such as when moving the ve-
hicle with the drive shaft removed.
Therefore, if it is absolutely necessary to place the ve-
hicle weight on the hub bearing, first support it with
the SST.
SST 09608±16042 (09608±02021, 09608±02041)

After disconnecting the drive shaft from the axle hub,
work carefully so as not to damage the ABS speed
sensor rotor serrations on the drive shaft.
1. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. REMOVE ENGINE UNDER COVER
3. DRAIN ATF
4. 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)
5. DISCONNECT TIE ROD END FROM STEERING
KNUCKLE
(a) Remove the cotter pin and nut.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
HINT:
At the time of installation, if the holes for a new cotter pin are not
aligned, tighten the nut further up to 60°.
(b) Using SST, disconnect the tie rod end from the steering
knuckle.
SST 09628±62011

F11617
F13342
F11614SST
SA±18
± SUSPENSION AND AXLEFRONT DRIVE SHAFT
2001 PRIUS (RM778U)
6. DISCONNECT LOWER BALL JOINT FROM LOWER
SUSPENSION ARM
Remove the 2 nuts and bolt.
Torque: 142 N´m (1,450 kgf´cm, 105 ft´lbf)
7. DISCONNECT DRIVE SHAFT FROM AXLE HUB
Using a plastic hammer, disconnect the drive shaft from the axle
hub.
NOTICE:
Be careful not to damage the boot and ABS speed sensor
rotor.
8. REMOVE DRIVE SHAFT
(a) Using SST, remove the drive shaft.
SST 09520±01010, 09520±24010 (09520±32040)
NOTICE:
Be careful not to damage the oil seal and dust cover.
HINT:
At the time of installation, please refer to the following items.

Apply gear oil to the inboard joint shaft and differential
case sliding surfaces.

Before installing the drive shaft, set the snap ring with its
opening side facing downward.

Whether inboard joint shaft is in contact with pinion shaft
or not can be known from the sound or feeling.

After installation, check that there is 2 ± 3 mm (0.08 ± 0.12
in.) of play in the axial direction.

After installation, check that the drive shaft cannot be re-
moved by hand.
(b) Using a screwdriver, remove the snap ring from the in-
board joint shaft.

SA1ZU±01
F11598
SST
F11599
F11593
Wood
F11618
± SUSPENSION AND AXLEREAR SHOCK ABSORBER
SA±51
2001 PRIUS (RM778U)
REMOVAL
1. REMOVE REAR WHEELS
Torque: 103 N´m (250 kgf´cm, 18 ft´lbf)
2. REMOVE REAR SEAT (See page BO±83)
3. DISCONNECT BRAKE LINES
(a) Using SST, disconnect the brake lines from the flexible
hose. Use a container to catch brake fluid as it drains out.
SST 09751±36011
(b) Remove the clip.
(c) Employ the same manner described above to the other
side.
4. DISCONNECT ABS SPEED SENSOR WIRE HARNESS
Remove the 4 nuts, and disconnect the ABS speed sensor wire
harness from the axle beam.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
5. SUPPORT REAR AXLE BEAM AT RIGHT AND LEFT
SIDES WITH JACKS
6. REMOVE SHOCK ABSORBER
(a) Remove the 2 nuts and bolt.
Torque: 80 N´m (816 kgf´cm, 59 ft´lbf)

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