2001 TOYOTA PRIUS power steering

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.

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)