Toyota Pius 2010 Operating instructions

2010 Toyota Prius Repair Manual
ILLUSTRATION

2010 Toyota Prius Repair Manual

2010 Toyota Prius Repair Manual
REMOVAL
NOTICE:
When the brake pedal is first depressed after replacing the brake pads or pushing back the disc
brake piston, DTC C1214 may be output. As there is no malfunction, clear the DTC.
HINT:
xUse the same procedure for the LH side and RH side.
xThe following 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 pin, and remove
the 2 bolts and disc brake cylinder assembly.
Text in Illustration
*1
Hold

2010 Toyota Prius Repair Manual
*2
Turn
6. REMOVE FRONT DISC BRAKE PAD
(a) Remove the 2 front disc brake pads from the front disc brake cylinder mounting.
7. REMOVE FRONT ANTI-SQUEAL SHIM
(a) Remove the front No. 1 anti
-
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 mounting.

2010 Toyota Prius Repair Manual
Text in Illustration
*1
Front No. 1 Disc Brake Pad Support Plate
*2
Front No. 2 Disc Brake Pad Support Plate
NOTICE:
Each front disc brake pad support plate has a different
shape. Be sure to put an identification mark on each front
disc brake pad support plate so 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) Remove the 2 front disc brake bushing dust boots from
the front disc brake cylinder mounting.

2010 Toyota Prius Repair Manual
12. REMOVE FRONT 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.

2010 Toyota Prius Repair Manual
DISASSEMBLY
1. REMOVE CYLINDER BOOT
(a) Using a screwdriver with its tip wrapped with vinyl
tape, remove the set ring and cylinder boot from the disc
brake cylinder assembly.
Text in Illustration
*1
Vinyl Tape
NOTICE:
Be careful not to damage 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 PISTON SEAL
(a) Using a screwdriver with its tip wrapped with vinyl

2010 Toyota Prius Repair Manual
tape, remove 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

2010 Toyota Prius Repair Manual
INSPECTION
1. INSPECT BRAKE CYLINDER AND PISTON
(a) Check the cylinder bore and piston for rust and scoring. If necessary, replace the disc brake
cylinder and piston.
2. INSPECT PAD LINING THICKNESS
(a) Using a ruler, measure the pad lining thickness.
Text in Illustration
*1
Ruler
Standard thickness:
10.0 mm (0.394 in.)
Minimum thickness:
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 off. 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
*1
Micrometer
Standard thickness:
25.0 mm (0.984 in.)
Minimum thickness:
22.0 mm (0.866 in.)
If the disc thickness is less than the minimum, replace the
front disc.
5. INSPECT DISC RUNOUT
(a) Inspect the front axle 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 from the axle
hub and speed sensor.