Download
Share
Print this page
Toyota Pius 2010 Repair Manual
  1. Manuals
  2. Brands
  3. Toyota Manuals
  4. Automobile
  5. Pius 2010
  6. Repair manual
Toyota Pius 2010 Repair Manual

Toyota Pius 2010 Repair Manual

Hide thumbs

Advertisement

Quick Links

Download this manual
ILLUSTRATION
2010 Toyota Prius
Repair Manual

Advertisement

loading

Related Manuals for Toyota Pius 2010

Summary of Contents for Toyota Pius 2010

  • Page 1 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 2 2010 Toyota Prius Repair Manual...
  • Page 3 5. REMOVE DISC BRAKE CYLINDER ASSEMBLY (a) Hold the front disc brake cylinder slide pin, and remove the 2 bolts and disc brake cylinder assembly. Text in Illustration Hold 2010 Toyota Prius Repair Manual...
  • Page 4 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 mounting. 2010 Toyota Prius Repair Manual...
  • Page 5 (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) Remove the 2 front disc brake bushing dust boots from the front disc brake cylinder mounting. 2010 Toyota Prius Repair Manual...
  • Page 6 (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 Matchmark HINT: Put matchmarks on the disc and the axle hub. 2010 Toyota Prius Repair Manual...
  • Page 7 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 PISTON SEAL (a) Using a screwdriver with its tip wrapped with vinyl 2010 Toyota Prius Repair Manual...
  • Page 8 Text in Illustration 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 2010 Toyota Prius Repair Manual...
  • Page 9 If necessary, replace the front disc brake pad support plates. 4. INSPECT DISC THICKNESS (a) Using a micrometer, measure the disc thickness. Text in Illustration 2010 Toyota Prius Repair Manual...
  • Page 10 (0.394 in.) away from the outer edge of the front disc. Text in Illustration Dial Indicator Maximum disc runout: 0.05 mm (0.00197 in.) NOTICE: Keep the magnet of the dial indicator away from the axle hub and speed sensor. 2010 Toyota Prius Repair Manual...
  • Page 11 If the disc thickness is less than the minimum, replace the front disc. (d) Remove the 5 nuts and front disc. 2010 Toyota Prius Repair Manual...
  • Page 12 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 in Illustration Cylinder Boot Front Disc Brake Piston 2010 Toyota Prius Repair Manual...
  • Page 13 (b) Using a screwdriver with its tip wrapped with vinyl tape, install a new set ring. Text in Illustration Vinyl Tape Securely install the set ring to the outer groove of the cylinder boot. Do not damage the cylinder boot. 2010 Toyota Prius Repair Manual...

  • Page 14: Installation

    (a) Apply a light layer of lithium soap base glycol grease to the entire circumference of 2 new front disc brake bushing dust boots. HINT: Apply at least 0.3 g (0.01 oz.) of lithium soap base glycol 2010 Toyota Prius Repair Manual...
  • Page 15 (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 CYLINDER SLIDE PIN 2010 Toyota Prius Repair Manual...
  • Page 16 *1 Front No. 1 Disc Brake Pad Support Plate *2 Front No. 2 Disc Brake Pad Support Plate NOTICE: Be sure to install each front disc brake pad support plate in the correct position and direction. 7. INSTALL FRONT ANTI-SQUEAL SHIM 2010 Toyota Prius Repair Manual...
  • Page 17 Make sure that disc brake grease is not applied onto the lining surface. 8. INSTALL FRONT DISC BRAKE PAD (a) Install the 2 front disc brake pads to the front disc brake cylinder mounting. 2010 Toyota Prius Repair Manual...
  • Page 18 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 LINE 12. PERFORM INITIALIZATION AND CALIBRATION OF LINEAR SOLENOID VALVE HINT: 2010 Toyota Prius Repair Manual...
  • Page 19 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) 2010 Toyota Prius Repair Manual...
  • Page 20 COMPONENTS ILLUSTRATION ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 21 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 22 2010 Toyota Prius Repair Manual...
  • Page 23 (a) Completely release the parking brake pedal. (b) Loosen the lock nut and adjusting nut to completely release the parking brake cable. Text in Illustration Lock Nut Adjusting Nut 8. DISCONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY 2010 Toyota Prius Repair Manual...
  • Page 24 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 the rear disc brake cylinder assembly. 2010 Toyota Prius Repair Manual...
  • Page 25 (a) Remove the rear No. 1 disc brake anti-squeal shim and rear No. 2 disc brake anti-squeal shim from each rear disc brake pad. Text in Illustration *1 Rear No. 1 Disc Brake Anti-squeal Shim *2 Rear No. 2 Disc Brake Anti-squeal Shim 2010 Toyota Prius Repair Manual...
  • Page 26 (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 cylinder mounting. 2010 Toyota Prius Repair Manual...
  • Page 27 (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 Matchmark HINT: Place matchmarks on the disc and axle hub. 2010 Toyota Prius Repair Manual...
  • Page 28 Text in Illustration 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. REMOVE REAR DISC BRAKE BLEEDER PLUG 2010 Toyota Prius Repair Manual...
  • Page 29 (a) Make sure that the rear disc brake pad support plates have sufficient rebound, no deformation, cracks or wear, and that all rust and dirt are removed. If necessary, replace the rear disc brake pad support plates. 4. INSPECT DISC THICKNESS (a) Using a micrometer, measure the disc thickness. 2010 Toyota Prius Repair Manual...
  • Page 30 (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 Dial Indicator Maximum disc runout: 0.15 mm (0.00591 in.) NOTICE: 2010 Toyota Prius Repair Manual...
  • Page 31 If the disc thickness is less than the minimum, replace the rear disc. (d) Remove the 5 nuts and rear disc. 2010 Toyota Prius Repair Manual...
  • Page 32 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 disc brake piston and a new cylinder boot. 2010 Toyota Prius Repair Manual...
  • Page 33 SST: 09960-10010 09963-00400 Securely install the cylinder boot to the groove of the piston. Do not damage the piston or cylinder boot. (c) Using SST, slowly return the piston until the piston 2010 Toyota Prius Repair Manual...
  • Page 34 (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 Cylinder Boot 2010 Toyota Prius Repair Manual...
  • Page 35 (a) Apply a light layer of lithium soap base glycol grease to the entire circumference of 2 new rear disc brake bushing dust boots. HINT: Apply at least 0.3 g (0.01 oz.) of lithium soap base glycol 2010 Toyota Prius Repair Manual...
  • Page 36 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 2010 Toyota Prius Repair Manual...
  • Page 37 (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 2010 Toyota Prius Repair Manual...
  • Page 38 Be sure to install the anti-squeal springs into the rear disc brake pad installation holes as far as they will go. 8. INSTALL REAR DISC BRAKE CYLINDER ASSEMBLY 2010 Toyota Prius Repair Manual...
  • Page 39 (a) Connect the rear flexible hose to the rear 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 2010 Toyota Prius Repair Manual...
  • Page 40 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. 2010 Toyota Prius Repair Manual...
  • Page 41 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) 2010 Toyota Prius Repair Manual...