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2010 Toyota Prius

Repair Manual

ILLUSTRATION

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Содержание Pius 2010

Страница 1: ...2010 Toyota Prius Repair Manual ILLUSTRATION ...

Страница 2: ...2010 Toyota Prius Repair Manual ...

Страница 3: ...llowing procedure is for the LH side 1 DISABLE BRAKE CONTROL 2 REMOVE FRONT WHEEL 3 DRAIN BRAKE FLUID NOTICE If brake fluid leaks onto any painted surface immediately wash it off 4 SEPARATE FRONT FLEXIBLE HOSE a Remove the union bolt and gasket and separate the front flexible hose from the disc brake cylinder assembly 5 REMOVE DISC BRAKE CYLINDER ASSEMBLY a Hold the front disc brake cylinder slide...

Страница 4: ...nti squeal shim and front No 2 anti squeal shim from each brake pad Text in Illustration 1 Front No 1 Anti squeal Shim 2 Front No 2 Anti squeal Shim b Remove the pad wear indicator plate from each front disc brake pad 8 REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE a Remove the 2 front No 1 disc brake pad support plates and 2 front No 2 disc brake pad support plates from the front disc brake cylinder ...

Страница 5: ...o that it can be reinstalled to its original position 9 REMOVE FRONT NO 1 DISC BRAKE CYLINDER SLIDE PIN a Remove the front No 1 disc brake cylinder slide pin from the front disc brake cylinder mounting 10 REMOVE FRONT NO 2 DISC BRAKE CYLINDER SLIDE PIN a Remove the front No 2 disc brake cylinder slide pin from the front disc brake cylinder mounting 11 REMOVE FRONT DISC BRAKE BUSHING DUST BOOT a Re...

Страница 6: ...ONT DISC BRAKE CYLINDER MOUNTING a Remove the 2 bolts and front disc brake cylinder mounting from the steering knuckle 13 REMOVE FRONT DISC a Remove the front disc Text in Illustration 1 Matchmark HINT Put matchmarks on the disc and the axle hub ...

Страница 7: ...mage the brake piston or cylinder 2 REMOVE FRONT DISC BRAKE PISTON a Place a piece of cloth between the front disc brake piston and disc brake cylinder assembly b Apply compressed air to remove the front disc brake piston from the disc brake cylinder assembly CAUTION Do not place your fingers in front of the piston when using compressed air NOTICE Do not allow any brake fluid to spatter 3 REMOVE P...

Страница 8: ...the piston seal from the disc brake cylinder assembly Text in Illustration 1 Vinyl Tape NOTICE Do not damage the inner surface or piston seal groove of the cylinder 4 REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP 5 REMOVE FRONT DISC BRAKE BLEEDER PLUG ...

Страница 9: ... 1 0 mm 0 0394 in If the pad lining thickness is less than the minimum thickness replace the disc brake pads HINT Be sure to check the wear of the front disc after replacing the brake pads with new ones 3 INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE a Make sure that the front disc brake pad support plates have sufficient rebound no deformation cracks or wear and that all rust and dirt are cleaned of...

Страница 10: ...e hub bearing looseness and front axle hub runout b Using SST to hold the disc tighten the disc with the 5 nuts SST 09330 00021 Torque 103 N m 1050 kgf cm 76ft lbf c Using a dial indicator measure the disc runout 10 mm 0 394 in away from the outer edge of the front disc Text in Illustration 1 Dial Indicator Maximum disc runout 0 05 mm 0 00197 in NOTICE Keep the magnet of the dial indicator away fr...

Страница 11: ...ue change the installation position of the disc to minimize the runout If the runout exceeds the maximum even when the installation position is changed grind the disc If the disc thickness is less than the minimum replace the front disc d Remove the 5 nuts and front disc ...

Страница 12: ... a Apply a light layer of lithium soap base glycol grease to the entire circumference of a new piston seal b Install the piston seal to the disc brake cylinder assembly NOTICE Securely install the piston seal into the groove of the disc brake cylinder 4 INSTALL FRONT DISC BRAKE PISTON a Apply a light layer of lithium soap base glycol grease to the entire circumference of a new cylinder boot Text i...

Страница 13: ...isc brake cylinder assembly 5 INSTALL CYLINDER BOOT a Install the cylinder boot to the disc brake cylinder assembly Text in Illustration 1 Set Ring 2 Cylinder Boot NOTICE Securely install the cylinder boot to the groove of the disc brake cylinder assembly and front disc brake piston b Using a screwdriver with its tip wrapped with vinyl tape install a new set ring Text in Illustration 1 Vinyl Tape ...

Страница 14: ...isc with a new one select the installation position where the front disc has minimal runout 2 INSTALL FRONT DISC BRAKE CYLINDER MOUNTING a Install the front disc brake cylinder mounting to the steering knuckle with the 2 bolts Torque 137 N m 1394 kgf cm 101ft lbf 3 INSTALL FRONT DISC BRAKE BUSHING DUST BOOT a Apply a light layer of lithium soap base glycol grease to the entire circumference of 2 n...

Страница 15: ...ER SLIDE PIN a Apply a light layer of lithium soap base glycol grease to the sliding part and the seal surface of the front No 2 disc brake cylinder slide pin b Install the front No 2 disc brake cylinder slide pin to the front disc brake cylinder mounting c Push the front No 2 disc brake cylinder slide pin into the front disc brake bushing dust boot to align them 5 INSTALL FRONT NO 1 DISC BRAKE CY...

Страница 16: ...cylinder slide pin into the front disc brake bushing dust boot to align them 6 INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE a Install the 2 front No 1 disc brake pad support plates and 2 front No 2 disc brake pad support plates to the front disc brake cylinder mounting Text in Illustration 1 Front No 1 Disc Brake Pad Support Plate 2 Front No 2 Disc Brake Pad Support Plate NOTICE Be sure to install e...

Страница 17: ... disc brake grease to the area that contacts the anti squeal shims c Install the front No 1 anti squeal shim and front No 2 anti squeal shim to each front disc brake pad Text in Illustration 1 Front No 1 Anti squeal Shim 2 Front No 2 Anti squeal Shim x Install the shims in the correct positions and directions x Disc brake grease can seep out slightly from the area where the anti squeal shim is ins...

Страница 18: ...front disc brake cylinder mounting with the 2 bolts Text in Illustration 1 Hold 2 Turn Torque 34 N m 347 kgf cm 25ft lbf 10 CONNECT FRONT FLEXIBLE HOSE a Connect the front flexible hose to the disc brake cylinder assembly with a new union bolt and a new gasket Torque 33 N m 340 kgf cm 25ft lbf HINT Install the flexible hose lock securely into the lock hole in the disc brake cylinder 11 BLEED BRAKE...

Страница 19: ... Toyota Prius Repair Manual If the brake control has been disabled make sure to perform initialization and calibration of the linear solenoid valve 13 INSTALL FRONT WHEEL Torque 103 N m 1050 kgf cm 76ft lbf ...

Страница 20: ...2010 Toyota Prius Repair Manual COMPONENTS ILLUSTRATION ILLUSTRATION ...

Страница 21: ...2010 Toyota Prius Repair Manual ILLUSTRATION ...

Страница 22: ...2010 Toyota Prius Repair Manual ...

Страница 23: ... 1 DISABLE BRAKE CONTROL 2 REMOVE REAR WHEEL 3 DRAIN BRAKE FLUID NOTICE If brake fluid leaks onto any painted surface immediately wash it off 4 REMOVE FRONT DOOR SCUFF PLATE LH 5 REMOVE COWL SIDE TRIM SUB ASSEMBLY LH 6 REMOVE LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY 7 LOOSEN PARKING BRAKE CABLE a Completely release the parking brake pedal b Loosen the lock nut and adjusting nut to completely r...

Страница 24: ... 1 No 3 Parking Brake Cable Assembly 2 Clip 3 Offset Wrench 14 mm HINT Insert an offset wrench 14 mm at the base of the No 3 parking brake cable assembly as shown in the illustration to disengage the clip Pull out the No 3 parking brake cable assembly from the rear disc brake cylinder assembly 9 SEPARATE REAR FLEXIBLE HOSE a Remove the union bolt and gasket and separate the rear flexible hose from...

Страница 25: ...s because the anti squeal springs may fall off the rear disc brake pads 11 REMOVE REAR DISC BRAKE PAD a Remove the 2 anti squeal springs from the rear disc brake pads b Remove the 2 rear disc brake pads from the rear disc brake cylinder mounting 12 REMOVE REAR DISC BRAKE ANTI SQUEAL SHIM a Remove the rear No 1 disc brake anti squeal shim and rear No 2 disc brake anti squeal shim from each rear dis...

Страница 26: ...a different shape Be sure to put an identification mark on each rear disc brake pad support plate so that it can be installed to its original position 14 REMOVE REAR DISC BRAKE PAD GUIDE PIN a Remove the 2 rear disc brake pad guide pins from the rear disc brake cylinder mounting 15 REMOVE REAR DISC BRAKE BUSHING DUST BOOT a Remove the 2 rear disc brake bushing dust boots from the rear disc brake c...

Страница 27: ...MOVE REAR DISC BRAKE CYLINDER MOUNTING a Remove the 2 bolts and rear disc brake cylinder mounting from the axle beam 17 REMOVE REAR DISC a Remove the rear disc Text in Illustration 1 Matchmark HINT Place matchmarks on the disc and axle hub ...

Страница 28: ...fluid to spatter 2 REMOVE CYLINDER BOOT a Remove the cylinder boot from the rear disc brake piston 3 REMOVE PISTON SEAL a Using a screwdriver with its tip wrapped with vinyl tape remove the piston seal from the rear disc brake cylinder assembly Text in Illustration 1 Vinyl Tape NOTICE Do not damage the inner surface or piston seal groove of the cylinder 4 REMOVE REAR DISC BRAKE BLEEDER PLUG CAP 5 ...

Страница 29: ... 1 0 mm 0 0394 in If the pad lining thickness is equal to the minimum thickness or less replace the brake pads with a disc brake pad kit HINT Be sure to check the wear of the rear disc after replacing the brake pads with new ones 3 INSPECT REAR DISC BRAKE PAD SUPPORT PLATE a Make sure that the rear disc brake pad support plates have sufficient rebound no deformation cracks or wear and that all rus...

Страница 30: ...CT DISC RUNOUT a Inspect the rear axle hub bearing looseness and axle hub runout b While holding the disc using SST tighten the disc with the 5 hub nuts SST 09330 00021 Torque 103 N m 1050 kgf cm 76ft lbf c Using a dial indicator with magnetic base measure the disc runout 10 mm 0 394 in away from the outer edge of the rear disc Text in Illustration 1 Dial Indicator Maximum disc runout 0 15 mm 0 00...

Страница 31: ...or If the runout exceeds the maximum value change the installation position of the disc to minimize the runout If the runout exceeds the maximum even when the installation position is changed grind the disc If the disc thickness is less than the minimum replace the rear disc d Remove the 5 nuts and rear disc ...

Страница 32: ...PISTON SEAL a Apply a light layer of lithium soap base glycol grease to the entire circumference of a new piston seal b Install the piston seal to the rear disc brake cylinder assembly NOTICE Securely install the piston seal to the groove of the rear disc brake cylinder assembly 4 INSTALL CYLINDER BOOT a Apply a light layer of lithium soap base glycol grease to the entire circumference of the rear...

Страница 33: ...f the cylinder boot into the groove portion of the rear disc brake cylinder assembly NOTICE Securely install the cylinder boot to the groove of the rear disc brake cylinder assembly b Using SST install the rear disc brake piston by turning it clockwise as far as possible SST 09960 10010 09963 00400 x Securely install the cylinder boot to the groove of the piston x Do not damage the piston or cylin...

Страница 34: ...sc brake cylinder assembly to the rear disc brake cylinder mounting align the piston groove with the protrusion on the rear disc brake pad d Make sure that the cylinder boot is securely installed into the groove of the rear disc brake cylinder assembly and rear disc brake piston Text in Illustration 1 Cylinder Boot ...

Страница 35: ...g the disc with a new one select the installation position where the rear disc has minimal runout 2 INSTALL REAR DISC BRAKE CYLINDER MOUNTING a Install the rear disc brake cylinder mounting to the axle beam with the 2 bolts Torque 57 N m 585 kgf cm 42ft lbf 3 INSTALL REAR DISC BRAKE BUSHING DUST BOOT a Apply a light layer of lithium soap base glycol grease to the entire circumference of 2 new rear...

Страница 36: ... rear disc brake cylinder mounting 4 INSTALL REAR DISC BRAKE PAD GUIDE PIN a Apply a light layer of lithium soap base glycol grease to the sliding and sealing surfaces of the 2 rear disc brake pad guide pins b Install the 2 rear disc brake pad guide pins to the rear disc brake cylinder mounting 5 INSTALL REAR DISC BRAKE PAD SUPPORT PLATE ...

Страница 37: ...isc brake pad support plate in the correct position and direction 6 INSTALL REAR DISC BRAKE ANTI SQUEAL SHIM a Apply disc brake grease to the back plate of the rear disc brake pads b Install the rear No 1 disc brake anti squeal shim and rear No 2 disc brake anti squeal shim to each rear disc brake pad Text in Illustration 1 Rear No 1 Disc Brake Anti squeal Shim ...

Страница 38: ...ed onto the lining surface 7 INSTALL REAR DISC BRAKE PAD a Install the 2 rear disc brake pads to the rear disc brake cylinder mounting NOTICE There should be no oil or grease on the friction surfaces of the disc brake pads or the rear disc b Install the 2 anti squeal springs to the rear disc brake pads x When replacing the rear disc brake pads with new ones make sure to replace the anti squeal spr...

Страница 39: ...e cylinder assembly to the rear disc brake cylinder mounting with the 2 bolts Text in Illustration 1 Hold 2 Turn Torque 34 N m 350 kgf cm 25ft lbf x Install the rear disc brake cylinder assembly while holding both of the rear disc brake pads because the anti squeal springs may fall off the rear disc brake pads x Be sure that the anti squeal springs are installed to the rear disc brake pads 9 CONNE...

Страница 40: ... assembly to the rear disc brake cylinder assembly Text in Illustration 1 No 3 Parking Brake Cable Assembly 2 Clip HINT Be sure to engage the No 3 parking brake cable assembly clip onto the rear disc brake cylinder assembly as shown in the illustration b Connect the No 3 parking brake cable assembly to the rear disc brake cylinder assembly ...

Страница 41: ...rake control has been disabled make sure to perform initialization and calibration of the linear solenoid valve 13 ADJUST PARKING BRAKE HINT 14 INSTALL LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY 15 INSTALL COWL SIDE TRIM SUB ASSEMBLY LH 16 INSTALL FRONT DOOR SCUFF PLATE LH 17 INSTALL REAR WHEEL Torque 103 N m 1050 kgf cm 76ft lbf ...

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