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.

2010 Toyota Prius Repair Manual
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 front disc.
(d) Remove the 5 nuts and front disc.

2010 Toyota Prius Repair Manual
REASSEMBLY
1. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
HINT:
Fully tighten the front disc brake bleeder plug after bleeding any air left in the system.
2. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
3. INSTALL 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 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 in Illustration
*1
Cylinder Boot
*2
Front Disc Brake Piston

2010 Toyota Prius Repair Manual
(b) Install the cylinder boot to the front disc brake piston.
(c) Apply a light layer of lithium soap base glycol grease to the contact surfaces of the front disc
brake piston, and install it to the disc brake cylinder assembly.
NOTICE:
Do not install the piston forcibly in the disc 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
x
Securely install the set ring to the outer groove of
the cylinder boot.
xDo not damage the cylinder boot.

2010 Toyota Prius Repair Manual
INSTALLATION
HINT:
xUse the same procedure for the LH side and RH side.
xThe following procedure is for the LH side.
1. INSTALL FRONT DISC
(a) Align the matchmarks of the disc and axle hub, and
install the disc.
Text in Illustration
*1
Matchmark
NOTICE:
When replacing the disc 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 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
grease to each front disc brake bushing dust boot.
(b) Install the 2 front disc brake bushing dust boots to the
front disc brake cylinder mounting.
4. INSTALL FRONT NO. 2 DISC BRAKE CYLINDER 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 cylinde
r 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 CYLINDER SLIDE PIN

2010 Toyota Prius Repair Manual
(a) Apply a light layer of lithium soap base glycol grease to
the sliding part and the seal surface of the front No. 1 disc
brake cylinder slide pin.
(b) Install the front No. 1 disc brake cylinder slide pin to
the front disc brake cylinder mounting.
(c) Push the front No. 1 disc brake 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 each front disc brake pad support plate in
the correct position and direction.
7. INSTALL FRONT ANTI-SQUEAL SHIM

2010 Toyota Prius Repair Manual
(a) Install the pad wear indicator plate to each front disc
brake pad.
NOTICE:
Install each pad wear indicator plate in the correct position
and
direction.
(b) Apply disc brake grease to both sides of each front No.
1 anti-squeal shim as shown in the illustration.
xWhen replacing worn pads, the front anti-squeal
shims must be replaced together with the pads.
xApply 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
xInstall 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 installed.
x
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
NOTICE:
There should be no oil or grease on the friction surfaces of
the disc brake pads or the front disc.
9. INSTALL DISC BRAKE CYLINDER ASSEMBLY
(a) Hold the front disc brake cylinder slide pin, and install
the disc brake cylinder assembly to the 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 LINE
12. PERFORM INITIALIZATION AND CALIBRATION OF LINEAR SOLENOID VALVE
HINT:

2010 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)

2010 Toyota Prius Repair Manual
COMPONENTS
ILLUSTRATION
ILLUSTRATION